Engine (Except Block)

Illustration	Tool Name	Tool Number
	Heavy Duty Floor Crane	014-00071 or equivalent
	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
	Alignment Plate, Camshaft	303-465 (T94P-6256-CH)
	Timing Peg, Crankshaft	303-507
	Holding Fixture, Drive Pinion Flange	205-126 (T78P-4851-A)
	Adapter for 205-126	(205-072-02)
	Installer, Front Oil Seal	303-096 (T74P-6150-A)
	Installer, Crankshaft Rear Main Oil Seal	303-328 (T88P-6701-B1)
	Aligner, Clutch Disc	308-006 (T71P-7137-H)

Fig 1: Exploded View Of Lower Engine Block

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Front Engine Block

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Cylinder Head

Courtesy of FORD MOTOR CO.

Fig 4: Exploded View Of Intake Manifold

Courtesy of FORD MOTOR CO.

All vehicles 

WARNING: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
1. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
2. Remove the engine plug bolt.
Fig 5: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
3. Install the special tool.
Fig 6: Identifying Special Tool (303-507)
Courtesy of FORD MOTOR CO.
4. If removed, install the halfshaft support bracket and bolts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 7: Locating Halfshaft Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
5. Install the oil pump assembly. Tighten the bolts in the sequence shown in 2 stages:
   • Stage 1: Tighten to 10 Nm (89 lb-in).
   • Stage 2: Tighten to 20 Nm (15 lb-ft).
Fig 8: Identifying Oil Pump Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
6. Install a new oil pump pickup tube gasket and the pickup tube.
   • Tighten to 10 Nm (89 lb-in).
Fig 9: Locating Oil Pump Pickup Tube Bolts
Courtesy of FORD MOTOR CO.
7. Using the special tool, install the crankshaft rear main oil seal.
Fig 10: Installing Crankshaft Rear Main Oil Seal Using Special Tool (303-328)
Courtesy of FORD MOTOR CO.
8. Tighten the crankshaft rear oil seal retainer bolts in the sequence shown.
   • To install, tighten to 10 Nm (89 lb-in).
Fig 11: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
Courtesy of FORD MOTOR CO.
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, which make leak paths. Use a plastic scraping tool to remove traces of sealant.
9. Clean and inspect all mating surfaces.
NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
10. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
Fig 12: Identifying Rear Oil Pan Bolts
Courtesy of FORD MOTOR CO.
11. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
Fig 13: Aligning Front Surface Of The Oil Pan
Courtesy of FORD MOTOR CO.
12. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
Fig 14: Identifying Tightening Sequence Of Oil Pan Bolts
Courtesy of FORD MOTOR CO.
13. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
Fig 15: Identifying Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
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 the head gasket.
CAUTION: Observe all warnings and 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.
14. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. 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.
15. Apply silicone gasket and sealant to the locations shown.
Fig 16: Identifying Silicone Gasket And Sealant Location
Courtesy of FORD MOTOR CO.
16. Install a new head gasket.
Fig 17: Locating Head Gasket
Courtesy of FORD MOTOR CO.
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
17. Install new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 15 Nm (11 lb-ft).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
Fig 18: Identifying Tightening Sequence Of Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
18. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages:
    • Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger tight.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (12 lb-ft).
Fig 19: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
19. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
    • The crankshaft sprocket flange must be facing away from the engine block.
Fig 20: Locating Washers, Oil Pump Chain & Sprockets
Courtesy of FORD MOTOR CO.
20. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 21: Locating Oil Pump Chain, Sprocket & Bolt
Courtesy of FORD MOTOR CO.

Late build vehicles 

21. Install the oil pump drive chain tensioner shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 22: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
Courtesy of FORD MOTOR CO.

Early build vehicles 

22. Install the oil pump drive chain guide and the shoulder bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 23: Installing Oil Pump Drive Chain Guide And Shoulder Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

23. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 24: Locating Oil Pump Chain Tensioner
Courtesy of FORD MOTOR CO.
CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
24. Install the special tool in the slots on the rear of both camshafts.
Fig 25: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
25. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
Fig 26: Locating Camshaft Sprocket Bolts
Courtesy of FORD MOTOR CO.
26. Install the LH timing chain guide and the bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 27: Identifying Bolts And LH Timing Chain Guide
Courtesy of FORD MOTOR CO.
27. Install the timing chain.
Fig 28: View Of Timing Chain
Courtesy of FORD MOTOR CO.
28. Install the RH timing chain guide.
Fig 29: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
29. Using the edge of a vise, compress the timing chain tensioner plunger.
Fig 30: Locating Timing Chain Tensioner Plunger
Courtesy of FORD MOTOR CO.
30. Using a small pick, push back and hold the ratchet mechanism.
Fig 31: Holding Ratchet Mechanism Using Small Pick
Courtesy of FORD MOTOR CO.
31. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Fig 32: Pushing Ratchet Arm Back Into Tensioner Housing
Courtesy of FORD MOTOR CO.
32. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
Fig 33: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet Assembly
Courtesy of FORD MOTOR CO.
33. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
Fig 34: Locating Timing Chain Tensioner Bolts And Paper Clip
Courtesy of FORD MOTOR CO.
CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
34. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • To install, tighten to 72 Nm (53 lb-ft).
Fig 35: Locating Camshaft Sprocket Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
35. Clean and inspect the mounting surfaces of the engine and the front cover.
NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
36. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
Fig 36: Locating Silicone Gasket
Courtesy of FORD MOTOR CO.
37. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
    • Tighten the 8 mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
Fig 37: Identifying Engine Front Cover Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Remove the through-bolt from the special tool.
NOTE: Lubricate the oil seal with clean engine oil.
38. Using the special tool, install a new crankshaft front oil seal.
Fig 38: Installing Crankshaft Front Oil Seal Using Special Tool
Courtesy of FORD MOTOR CO.
CAUTION: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
39. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
Fig 39: Locating Crankshaft Pulley & Hole
Courtesy of FORD MOTOR CO.
CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
40. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
Fig 40: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
41. Assemble the special tools using 4 hardened washers in the locations shown.
Fig 41: Assembling Special Tools (205-126 And 205-072-02)
Courtesy of FORD MOTOR CO.
CAUTION: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.
CAUTION: Do not reuse the crankshaft pulley bolt.
42. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
Fig 42: Using Special Tools (205-126 And 205-072-02)
Courtesy of FORD MOTOR CO.
43. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
Fig 43: Aligning Crankshaft Pulley Bolt Holes
Courtesy of FORD MOTOR CO.
44. Remove the special tool.
Fig 44: Identifying Special Tool
Courtesy of FORD MOTOR CO.
45. Remove the special tool.
Fig 45: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
46. Turn the crankshaft clockwise 1 and 3/4 turns.
47. Install the special tool.
Fig 46: Identifying Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
48. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
Fig 47: Identifying Special Tool (303-507)
Courtesy of FORD MOTOR CO.
CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
49. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected.
Fig 48: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
Courtesy of FORD MOTOR CO.
50. Using the special tool, check the position of the camshafts.
    • If it is not possible to install the special tool, the engine valve timing must be corrected.
Fig 49: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
51. Remove the special tool.
Fig 50: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
52. Install a new CKP sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
Fig 51: Locating CKP Sensor
Courtesy of FORD MOTOR CO.
NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.
53. Adjust the CKP sensor with the alignment tool.
    • Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
Fig 52: Locating CKP Sensor Alignment Tool And Bolts
Courtesy of FORD MOTOR CO.
54. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
Fig 53: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
Courtesy of FORD MOTOR CO.
55. Remove the special tool.
Fig 54: Identifying Special Tool
Courtesy of FORD MOTOR CO.
56. Install the engine plug bolt.
    • Tighten to 20 Nm (15 lb-ft).
Fig 55: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
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 which make leak paths.
57. Clean the valve cover gasket surface with metal surface cleaner.
58. Apply silicone gasket and sealant to the locations shown.
Fig 56: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
59. Install the valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
Fig 57: Identifying Valve Cover Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
60. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
    • Tighten the CHT sensor to 12 Nm (9 lb-ft).
    • Tighten the spark plugs to 12 Nm (9 lb-ft).
Fig 58: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs
Courtesy of FORD MOTOR CO.
NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
61. Install the coil-on-plugs, bolts and the crankcase vent tube.
    • Tighten to 10 Nm (89 lb-in).
Fig 59: Locating Crankcase Vent Tube And Coil-On-Plugs
Courtesy of FORD MOTOR CO.
62. If equipped, install the block heater.
    • Tighten to 21 Nm (15 lb-ft).
Fig 60: Locating Block Heater
Courtesy of FORD MOTOR CO.
NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
63. Install the crankcase vent oil separator and the KS.
    • Tighten the oil separator bolts to 10 Nm (89 lb-in).
    • Tighten the KS to 20 Nm (15 lb-ft).
Fig 61: Locating Crankcase Vent Oil Separator, KS And Bolts
Courtesy of FORD MOTOR CO.
64. Install the coolant hoses.
Fig 62: Locating Coolant Hoses
Courtesy of FORD MOTOR CO.
65. Install the coolant hose.
Fig 63: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
66. Install the coolant hose.
Fig 64: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
67. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
Fig 65: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
Courtesy of FORD MOTOR CO.
68. Attach the wiring harness retainer.
Fig 66: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
69. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
Fig 67: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-Plug
Courtesy of FORD MOTOR CO.
70. Connect the exhaust gas recirculation (EGR) valve and radio interference capacitor electrical connectors. Attach the wiring harness retainer.
Fig 68: Locating EGR Valve & Radio Interference Capacitor Electrical Connectors
Courtesy of FORD MOTOR CO.
71. Attach the wiring harness retainer.
Fig 69: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
72. Install new fuel injector O-rings.
    • Separate the fuel injectors from the fuel rail.
    • Remove and discard the fuel injector O-rings.
    • Install new O-rings and lubricate with clean engine oil.
    • Install the fuel injectors onto the fuel rail.
Fig 70: Identifying Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.
73. Install the fuel rail with the fuel injectors and bolts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 71: Locating Fuel Rail With Fuel Injectors & Bolts
Courtesy of FORD MOTOR CO.
74. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
Fig 72: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
75. Install the EGR tube.
    • Tighten to 55 Nm (41 lb-ft).
Fig 73: Locating Exhaust Gas Recirculation (EGR) Tube
Courtesy of FORD MOTOR CO.
76. Position the intake manifold and connect the positive crankcase ventilation hose.
Fig 74: Locating Positive Crankcase Ventilation Hose
Courtesy of FORD MOTOR CO.
NOTE: Inspect and install new intake manifold gaskets, if necessary.
77. Install the intake manifold gaskets and intake manifold.
    • Tighten the bolts to 18 Nm (13 lb-ft).
Fig 75: Locating Intake Manifold Gaskets & Intake Manifold
Courtesy of FORD MOTOR CO.
78. Connect the throttle position (TP) sensor electrical connector.
Fig 76: Locating Throttle Position (TP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
79. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
Fig 77: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
80. Connect the swirl control valve electrical connector.
Fig 78: Locating Swirl Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
81. Connect the idle air control (IAC) motor electrical connector.
Fig 79: Locating Idle Air Control (IAC) Motor Electrical Connector
Courtesy of FORD MOTOR CO.
82. Connect the temperature manifold absolute pressure (TMAP) electrical connector.
Fig 80: Locating Temperature Manifold Absolute Pressure (TMAP) Electrical Connector
Courtesy of FORD MOTOR CO.
83. Connect the KS and attach the 2 wiring harness retainers.
Fig 81: Locating Knock Sensor (KS) & Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
84. Attach the 2 wiring harness retainers.
Fig 82: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
85. If removed, install the capacitor and bolt.
    • Tighten to 20 Nm (15 lb-ft).
Fig 83: Locating Capacitor & Bolt
Courtesy of FORD MOTOR CO.
CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
86. Position the oil filter adapter in a vise and install the oil filter, new oil cooler and oil cooler bolt.
    • Tighten the oil cooler bolt to 34 Nm (25 lb-ft).
    • Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
NOTE: Clean the gasket mating surfaces with metal surface cleaner.
87. Install the oil filter adapter with a new gasket.
    • Tighten to 25 Nm (18 lb-ft).
Fig 84: Locating Oil Filter Adapter And Bolts
Courtesy of FORD MOTOR CO.
88. Install a new oil filter.
    • Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
Fig 85: Locating Engine Oil Filter
Courtesy of FORD MOTOR CO.
89. Connect the oil pressure sensor electrical connector.
Fig 86: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil prior to installing.
90. Install the oil level indicator and bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 87: Locating Oil Level Indicator & Bolts
Courtesy of FORD MOTOR CO.
NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.
91. Install the thermostat housing and bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 88: Locating Thermostat Housing & Bolts
Courtesy of FORD MOTOR CO.
92. Attach the 2 wiring harness retainers.
Fig 89: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
93. Install the engine vacuum tube.
    • Connect the engine vacuum tube.
    • Attach the 2 engine vacuum tube retainers.
Fig 90: Locating Engine Vacuum Tube
Courtesy of FORD MOTOR CO.
NOTE: Clean the coolant pump mating surface with metal surface cleaner.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
94. Install the coolant pump and bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 91: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
95. Install the coolant pump pulley and bolts.
    • Tighten to 20 Nm (15 lb-ft).
Fig 92: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
96. If equipped, install the accessory drive belt idler pulley.
    • Tighten to 25 Nm (18 lb-ft).
Fig 93: Locating Accessory Drive Belt Idler Pulley And Bolt
Courtesy of FORD MOTOR CO.
97. Install the accessory drive belt idler pulley.
    • Tighten to 25 Nm (18 lb-ft).
Fig 94: Locating Accessory Drive Belt Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
98. Install the generator and bolts.
    • Tighten to 47 Nm (35 lb-ft).
Fig 95: Locating Generator & Bolts
Courtesy of FORD MOTOR CO.
99. Position a new exhaust manifold gasket on the engine.
CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
NOTE: Make sure to tighten the nuts in the sequence in 2 stages.
100. Position the catalytic converter and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages:
     • Stage 1: Tighten to 47 Nm (35 lb-ft).
     • Stage 2: Tighten to 47 Nm (35 lb-ft).
Fig 96: Identifying Tightening Sequence Of Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
101. Install the heat shield and the 6 bolts.
     • Tighten to 10 Nm (89 lb-in).
Fig 97: Locating Heat Shield & Bolts
Courtesy of FORD MOTOR CO.
102. Install the 2 catalytic converter bracket bolts.
     • Tighten to 25 Nm (18 lb-ft).
Fig 98: Locating Lower Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
103. Connect the generator electrical connections and install the nut.
     • Tighten to 6 Nm (53 lb-in).
Fig 99: Locating Generator Electrical Connections
Courtesy of FORD MOTOR CO.
104. Connect the CKP sensor electrical connector.
Fig 100: Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
105. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.

Vehicles with automatic transaxle 

106. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in 3 stages:
     • Stage 1: Tighten to 50 Nm (37 lb-ft).
     • Stage 2: Tighten to 80 Nm (59 lb-ft).
     • Stage 3: Tighten to 112 Nm (83 lb-ft).
Fig 101: Identifying Flexplate Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.

Vehicles with manual transaxle 

107. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in 3 stages:
     • Stage 1: Tighten to 50 Nm (37 lb-ft).
     • Stage 2: Tighten to 80 Nm (59 lb-ft).
     • Stage 3: Tighten to 112 Nm (83 lb-ft).
Fig 102: Identifying Flexplate Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
108. Install the starter motor isolator.
Fig 103: Locating Starter Motor Isolator
Courtesy of FORD MOTOR CO.
109. Lubricate the transaxle input shaft pilot bearing with front axle grease.
Fig 104: Locating Transmission Input Shaft Pilot Bearing
Courtesy of FORD MOTOR CO.
110. Using the special tool, position the clutch disc on the flywheel.
Fig 105: Positioning Clutch Disc On Flywheel Using Special Tool (308-006)
Courtesy of FORD MOTOR CO.
NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
111. Position the clutch pressure plate and install the bolts.
     • Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.