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WARNING: This page is about a different car, the 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
- Clean all gasket mating surfaces. Use a plastic scraping tool, silicone gasket remover, if necessary and metal surface prep. Follow the directions on the packaging.
- Remove any large deposits of silicone or gasket material with a plastic scraper.
- Apply silicone gasket remover, following package directions and allow to set for several minutes.
- Remove the silicone gasket remover with a plastic scraping tool. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
- Apply metal surface prep, following package directions, to remove any traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
- If necessary, install the following:
- Cylinder block dowels.
- Oil gallery plugs.
- Water jacket plugs.
- Using the Camshaft Service Set, install the engine dynamic balance shaft bearings.
- Using the Camshaft Service Set, install the camshaft bearings.
- Install the following:
- Engine dynamic balance shaft bearing cover
- Camshaft bearing cover
- If equipped, install the block heater.
- Tighten to 2 Nm (18 lb-in).
- Install the 3 crankshaft upper main bearings and the crankshaft upper thrust main bearing.
- Position the crankshaft.
- Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket and sealant to the rear main bearing cap-to-cylinder block parting line.
- Install the 4 main bearing caps. Tighten the bolts in 2 stages.
- Stage 1: Tighten to 55 N.m (41 lb-ft).
- Stage 2: Rotate an additional 90 degrees.
- Using a piston ring compressor, compress the piston rings.
- Install the piston with the arrow on the piston face pointing toward the front of the engine.
- Position the lower connecting rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal.
- Tighten the 2 connecting rod cap bolts in 3 stages.
- Stage 1: Tighten to 25 N.m (18 lb-ft).
- Stage 2: Tighten to 45 N.m (33 lb-ft).
- Stage 3: Tighten an additional 105 degrees.
- Install the remaining pistons and the connecting rods.
- Install the oil pan baffle and the 5 retaining nuts.
- Tighten to 32 Nm (24 lb-ft).
- Using a new gasket, position the oil pump screen cover and tube and install the 2 bolts and the nut.
- Tighten the bolts to 25 Nm (18 lb-ft).
- Tighten the nut to 32 Nm (24 lb-ft).
- Install the camshaft, camshaft spacer and camshaft key.
- Install the camshaft thrust plate and 2 bolts.
- Tighten to 11 Nm (8 lb-ft).
- Install the engine dynamic balance shaft assembly and 2 bolts.
- Tighten to 11 Nm (8 lb-ft).
- Install the engine balance shaft drive gear so that the timing mark lines up with the timing mark on the engine balance shaft driven gear.
- Install the 12 valve tappets.
- Install the 12 valve tappets.
- Install the tappet guide plates.
- Install the 4 bolts and tighten to 12 Nm (9 lb-ft).
- Install the timing chain tensioner and 2 bolts.
- Position the timing chain tensioner.
- Install the 2 bolts and tighten to 11 Nm (8 lb-ft).
- If necessary, compress the tensioner pad and install a retaining pin.
- Rotate the crankshaft so the No. 1 piston is at top dead center (TDC) and the keyway is at the 12 o'clock position.
- Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
- Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
- Make sure the timing marks and the keyways are aligned.
- Remove the retaining pin.
- Install the synchronizer drive gear and the bolt.
- Tighten to 45 Nm (33 lb-ft).
- Install the engine front cover studs in their original locations.
- Tighten the engine front cover studs to 7 Nm (62 lb-in).
- Using a new gasket, install the engine front cover.
- Using a new gasket, install the coolant pump.
- Tighten the fasteners in the sequence shown.
- Tighten capscrew No. 12 to 10 Nm (89 lb-in).
- Tighten all other fasteners to 28 Nm (21 lb-ft).
- Using the special tools, install the crankshaft front seal.
- Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper and use the special tool to install the crankshaft damper.
- Using the special tool to prevent crankshaft rotation, install the bolt.
- Tighten to 160 Nm (118 lb-ft).
- Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
- Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 54 degrees from the centerline of the engine.
- Install the camshaft synchronizer retaining bolt.
- Tighten to 25 Nm (18 lb-ft).
- Install the camshaft position (CMP) sensor and the 2 bolts.
- Tighten to 6 Nm (53 lb-in).
- Apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.
- Apply silicone gasket and sealant to the rear main bearing cap.
- Install the oil pan rear seal.
- Apply silicone gasket and sealant to the oil pan sealing surface.
- Tighten the 17 oil pan bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
- Using new gaskets, install the RH and the LH cylinder heads.
- Install the new bolts. Make sure the bolts are installed in the correct locations.
- Install the new long bolts.
- Install the new short bolts.
- Tighten the bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten to 40 Nm (30 lb-ft).
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Carry out the following final tightening process on each bolt in the sequence shown.
- Long bolts:
- Loosen and back out 3 turns.
- Tighten to 45 Nm (33 lb-ft).
- Tighten an additional 180 degrees.
- Continue on to the next bolt in sequence.
- Short bolts:
- Loosen and back out 3 turns.
- Tighten to 25 Nm (18 lb-ft).
- Tighten an additional 180 degrees.
- Continue on to the next bolt in sequence.
- Long bolts:
- Install the 12 push rods.
- Install the 12 rocker arms.
- Position the 12 rocker arms and pivots.
- Hand-start the 12 bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
- Install the RH engine support insulator bracket and the 3 bolts.
- Tighten to 48 Nm (35 lb-ft).
- Inspect the RH exhaust manifold gasket sealing surfaces for flatness. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (9 lb-ft).
- Using a new gasket, install the RH exhaust manifold. Loosely install 6 new nuts.
- Tighten the 6 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
- Install a new RH valve cover gasket. Position the RH valve cover and install the bolts and stud bolts.
- Tighten to 10 Nm (89 lb-in).
- Install the following:
- The LH engine support insulator and the bolts.
- Tighten to 48 Nm (35 lb-ft).
- The oil pressure sender.
- Tighten to 27 Nm (20 lb-ft).
- The LH engine support insulator and the bolts.
- Inspect the LH exhaust manifold gasket sealing surfaces for flatness. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (9 lb-ft).
- Using a new gasket, install the LH exhaust manifold. Loosely install 6 new nuts.
- Tighten the new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
- Install the oil level indicator tube and the retaining bolt.
- Tighten to 10 Nm (89 lb-in).
- Install a new valve cover gasket. Position the RH valve cover and install the bolts and stud bolts.
- Tighten to 10 Nm (89 lb-in).
- Install the lower intake manifold front and rear seals.
- Apply a bead of silicone gasket and sealant to the intake manifold front and rear seal mounting points as indicated.
- Install the lower intake manifold front and rear seals.
- Install the intake manifold gaskets.
- Position the lower intake manifold.
- Apply a bead of silicone gasket and sealant to the lower intake manifold gaskets and front and rear seal junctions in 4 places as shown.
- Position the lower intake manifold.
- Tighten the 14 bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 5 N.m (44 lb-in).
- Stage 2: Tighten to 10 N.m (89 lb-in).
- Position the heater outlet tube and install the nut. Connect the bypass hose.
- Tighten to 10 Nm (89 lb-in).
- Position the coolant pump pulley and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Position the engine wiring harness on the engine.
- Connect and attach the HO2S electrical connector. Connect the knock sensor (KS) and the cylinder head temperature (CHT) sensor electrical connectors.
- Connect the oil pressure sender electrical connector and attach the wiring harness retainer.
- Position the A/C compressor and power steering pump bracket and, if equipped, the A/C compressor and install the bolt finger tight.
- Position the A/C and power steering pump bracket brace and install the 2 bolts and 2 nuts.
- Tighten the 2 bolts to 48 Nm (35 lb-ft).
- Tighten the 2 nuts to 25 Nm (18 lb-ft).
- If equipped, attach the wiring harness retainer and connect the A/C compressor clutch electrical connector.
- Connect the crankshaft position (CKP) sensor and the camshaft position (CMP) electrical connectors.
- Attach the 2 wiring harness retainers.
- Position the generator mounting bracket, the generator, the accessory drive belt tensioner and the idler pulley as an assembly and install the 4 bolts.
- Tighten the 3 lower bolts to 48 Nm (35 lb-ft).
- Tighten the upper bolt to 25 Nm (18 lb-ft).
- Install the accessory drive belt idler pulley and the bolt.
- Tighten to 55 Nm (41 lb-ft).
- Connect the heated positive crankcase ventilation (PCV) valve and the radio interference capacitor electrical connectors.
- Connect and attach the heated oxygen sensor (HO2S) electrical connector. Install the ground wire and the nut.
- Install the special tool to the RH side.
- Install the special tool the LH side.
- Install the special tool.
- Attach an engine crane to the Engine Lifting Bracket. Remove the engine from the stand.
- Assemble the special tools and the crankshaft rear seal.
- Install the special tools on the rear of the crankshaft.
- Install the crankshaft rear seal. Tighten the center jack screw (303-S560) until the spacer (303-561) contacts the engine block.
- Install the engine-to-transmission spacer plate.
CAUTION:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of old gasket.
CAUTION:
Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE:
If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
CAUTION:
Make sure the components are installed in the correct locations.
NOTE:
Lubricate the crankshaft main bearings with clean engine oil prior to installation.
CAUTION:
The crankshaft journals must be protected from damage when installing the crankshaft.
CAUTION:
The main bearings are precision selective fit. Inspect the bearing clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION
article.
NOTE:
If the rear main bearing cap is not installed within 4 minutes, remove the sealant and reapply.
CAUTION:
Inspect the piston clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION
article.
CAUTION:
Do not damage the cylinder wall with the sharp edges of the connecting rod.
CAUTION:
Inspect the connecting rod bearing clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION
article.
CAUTION:
The connecting rod cap will fit only one way.
CAUTION:
Do not damage the camshaft lobes when installing the camshaft.
NOTE:
If correctly aligned, the engine dynamic balance shaft timing mark will be at the 6 o'clock position and the camshaft timing mark will be at the 12 o'clock position on the camshaft.
NOTE:
Lubricate the valve tappets with clean engine oil prior to installing. If reusing the valve tappets, make sure to install them in their original locations.
CAUTION:
All timing marks must be aligned with the No. 1 cylinder set on TDC of the compression stroke or the synchronizer assembly will not be installed correctly.
NOTE:
The crankshaft must not be turned until the camshaft synchronizer is installed.
NOTE:
Use thread sealant with PTFE on studs No. 4 and 6 and bolt No. 12.
CAUTION:
The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
NOTE:
Lubricate the crankshaft front seal with clean engine oil.
CAUTION:
After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed and the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression stroke on the No. 1 cylinder.
CAUTION:
A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.
Fig 33: Installing Special Tool On Camshaft Synchronizer By Rotating Tool Until It Engages Notch In Camshaft Synchronizer Housing
NOTE:
Always coat the synchronizer drive gear with clean engine oil prior to installation.
NOTE:
During installation, the arrow on the special tool will rotate clockwise as the gears engage.
Fig 34: Installing Camshaft Synchronizer Housing Assembly So Arrow On Synchronizer Alignment Tool Is 54 Degrees From Centerline Of The Engine
NOTE:
If the oil pan is not installed within 4 minutes, remove the sealant and reapply. Use silicone gasket remover and metal surface prep. Follow the directions on the packaging.
NOTE:
The 2 oil pan-to-engine front cover bolts are unique and must be installed in the correct positions.
CAUTION:
Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
CAUTION:
The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION:
The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
NOTE:
Install the new cylinder head gaskets with the small hole to the front of the engine.
CAUTION:
Always use new bolts.
NOTE:
Lubricate the bolts with clean engine oil prior to installation.
CAUTION:
Each bolt must be loosened and the final tightening carried out prior to working on the next bolt in the sequence. Do not loosen all of the bolts at one time.
NOTE:
Lubricate the push rods with clean engine oil prior to installation. If reusing the push rods, make sure to install them in their original locations.
NOTE:
If reusing the rocker arms, make sure to install them in their original locations.
NOTE:
Make sure the 2 long studs are installed in the locations noted during removal.
NOTE:
Install a new oil level indicator tube O-ring seal. Lubricate the O-ring seal with clean engine oil.
NOTE:
If the lower intake manifold is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE:
If the lower intake manifold is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE:
Make sure the bolts are installed in the correct locations. The long bolts are installed in positions 1, 2, 3, 4, 11 and 12.
NOTE:
Clean and inspect the O-ring seal. Install a new O-ring seal if necessary. Lubricate the O-ring seal with clean engine coolant.
NOTE:
Use two 10 mm (3/8 in) spring links to connect the Engine Lifting Bracket 303-F047 to the Engine Lifting Bracket 303-050.
NOTE:
Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.