Section 1991 (Engine - 2.3L - (Hybrid)): Assembly: Engine

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)

Fig 1: Exploded View Of Lower Engine Block Components (View 1)

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Lower Engine Block Components (View 2)

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Front Engine Block Components

Courtesy of FORD MOTOR CO.

Fig 4: Exploded View Of Cylinder Head Components

Courtesy of FORD MOTOR CO.

Fig 5: Exploded View Of Intake Manifold Components

Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.
NOTE: The front bulkhead does not have an oil squirter.
Fig 6: Locating Oil Squirters
Courtesy of FORD MOTOR CO.
1. Install the 4 oil squirters.

   Tighten to 4 Nm (35 lb-in).

2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
Fig 7: Measuring Crankshaft Main Bearing Journals
Courtesy of FORD MOTOR CO.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
Fig 8: Positioning Main Bearing Beam
Courtesy of FORD MOTOR CO.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
   • Tighten the bolts in the sequence shown in 3 stages.
   • Stage 1: Tighten to 5 Nm (44 lb-in).
   • Stage 2: Tighten to 25 Nm (18 lb-ft).
   • Stage 3: Tighten an additional 90 degrees.
Fig 9: Main Bearing Beam Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
5. Measure each crankshaft block housing main bearing bore diameter.
   • Remove the bolts and the main bearing beam.
   • Discard the main bearing beam bolts.
Fig 10: Measuring Main Bearing Bore Diameter
Courtesy of FORD MOTOR CO.
6. Using the chart, select the crankshaft main bearings
Fig 11: Crankshaft Main Bearing Chart
Courtesy of FORD MOTOR CO.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts.
   1. Tighten the bolts in 2 stages.
   2. Stage 1: Tighten to 29 Nm (21 lb-ft).
   3. Stage 2: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
   • Remove the bolts and the connecting rod cap.
   • Discard the connecting rod cap bolts.
Fig 12: Measuring Connecting Rod Large End Bore
Courtesy of FORD MOTOR CO.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
   Fig 13: Measuring Crankshaft Connecting Rod Journal Diameter

   Courtesy of FORD MOTOR CO.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
Fig 14: Connecting Rod Bearing Chart
Courtesy of FORD MOTOR CO.
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
NOTE: The center bulkhead is the thrust bearing.
11. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
Fig 15: Aligning Front Surface Of The Oil Pan
Courtesy of FORD MOTOR CO.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
Fig 16: Identifying Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.
    Fig 17: Positioning Crankshaft In Cylinder Block

    Courtesy of FORD MOTOR CO.
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
Fig 18: Identifying Main Bearing Side Fit Surfaces
Courtesy of FORD MOTOR CO.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    Fig 19: Locating Crankshaft Bearing Journals

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.
17. Install and tighten the 10 new main bearing beam bolts.
    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
Fig 20: Identifying Tightening Sequence Of Main Bearing Beam Bolts
Courtesy of FORD MOTOR CO.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
    • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge with Holding Fixture.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
Fig 21: Measuring Crankshaft End Play
Courtesy of FORD MOTOR CO.
NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
    • When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
    • The position of the upper and lower compression ring gaps are not controlled for installation.
Fig 22: Locating Piston Ring Compressor
Courtesy of FORD MOTOR CO.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
20. Install the connecting rod caps and the new bolts.
    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
Fig 23: Locating Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
21. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).
Fig 24: Locating Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
NOTE: The original adjustment shims must be installed in their original position.
NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.
22. Install the adjustment shims in their original position on the seat faces of the balancer unit.
23. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
Fig 25: Locating Balancer Unit Shaft Marks
Courtesy of FORD MOTOR CO.
24. Install the balancer unit bolts.
    1. Tighten in the sequence shown in 2 stages.
    2. Stage 1: Tighten to 25 Nm (18 lb-ft).
    3. Stage 2: Tighten to 50 Nm (37 lb-ft).
Fig 26: Balancer Unit Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
25. Remove the Crankshaft TDC Timing Peg.
Fig 27: Locating Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
27. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the CrankshaftTDC Timing Peg.
    1. Remove the Crankshaft TDC Timing Peg.
Fig 28: Locating Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown.
28. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
    1. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    2. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
    3. Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
    4. If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure.
Fig 29: Positioning Dial Indicator Gauge
Courtesy of FORD MOTOR CO.
NOTE: 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.
29. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
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.
30. Install the special tool.
Fig 30: Locating Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
31. Install the block-off plate and bolts.
    1. Tighten to 25 Nm (18 lb-ft).
Fig 31: Locating Block Off Plate Bolts
Courtesy of FORD MOTOR CO.
NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
Fig 32: Oil Pump Assembly Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
32. Install the oil pump assembly. Tighten the bolts in the sequence shown in the following 2 stages:
    1. Stage 1: Tighten to 10 Nm (89 lb-in).
    2. Stage 2: Tighten to 20 Nm (15 lb-ft).
33. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 Nm (89 lb-in).
Fig 33: Locating Oil Pump Pickup Tube
Courtesy of FORD MOTOR CO.
34. Using the special tool, install the crankshaft rear main oil seal.
Fig 34: Locating Special Tool On Rear Main Oil Seal
Courtesy of FORD MOTOR CO.
35. Tighten the crankshaft rear main oil seal bolts in the sequence shown.

    Tighten to 10 Nm (89 lb-in).

    Fig 35: Crankshaft Rear Main Oil Seal Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
NOTE: 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 and metal surface cleaner to remove traces of sealant
36. 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.
37. 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 36: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
38. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
Fig 37: Aligning Front Surface Of Oil Pan
Courtesy of FORD MOTOR CO.
39. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.

    Tighten to 25 Nm (18 lb-ft).

Fig 38: Oil Pan Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: 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.
NOTE: 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.
40. 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.
41. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
42. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
Fig 39: Locating Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
43. Apply silicone gasket and sealant to the locations shown
Fig 40: Silicone Gasket Application Areas
Courtesy of FORD MOTOR CO.
44. Install a new head gasket.
Fig 41: Identifying 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.
45. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in the following 5 stages:
    1. Stage 1: Tighten to 5 Nm (44 lb-in).
    2. Stage 2: Tighten to 15 Nm (11 lb-ft).
    3. Stage 3: Tighten to 45 Nm (33 lb-ft).
    4. Stage 4: Turn 90 degrees.
    5. Stage 5: Turn an additional 90 degrees.
Fig 42: Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: 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.
46. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
    1. Stage 1: Tighten 1 turn at a time until tight.
    2. Stage 2: Tighten to 7 Nm (62 lb-in).
    3. Stage 3: Tighten to 16 Nm (12 lb-ft).
       Fig 43: 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.
47. 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 44: Identifying Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
48. Install the oil pump chain, sprocket and bolt.

    Tighten to 25 Nm (18 lb-ft).

    Fig 45: Identifying Oil Pump Chain, Sprocket And Bolt

    Courtesy of FORD MOTOR CO.

Late build vehicles 

49. Install the oil pump drive chain tensioner shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 46: Locating Oil Pump Drive Chain Tensioner Shoulder Bolt
Courtesy of FORD MOTOR CO.

Early build vehicles 

50. Install the oil pump drive chain guide and the shoulder bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 47: Locating Oil Pump Drive Chain Guide And Shoulder Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

51. 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 48: Identifying Oil Pump Drive Chain Tensioner
Courtesy of FORD MOTOR CO.
NOTE: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
52. Install the special tool in the slots on the rear of both camshafts.
Fig 49: Locating Camshaft Alignment Tool
Courtesy of FORD MOTOR CO.
53. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
Fig 50: Locating Camshaft Sprockets And Bolts
Courtesy of FORD MOTOR CO.
54. Install the LH timing chain guide and the bolts.

    Tighten to 10 Nm (89 lb-in).

Fig 51: Locating LH Timing Chain Guide Bolts
Courtesy of FORD MOTOR CO.
55. Install the timing chain.
Fig 52: Locating Timing Chain
Courtesy of FORD MOTOR CO.
56. Install the RH timing chain guide.
    Fig 53: Locating RH Timing Chain Guide

    Courtesy of FORD MOTOR CO.
    NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Fig 54: Locating Timing Chain Tensioner Plunger
Courtesy of FORD MOTOR CO.
57. Using the edge of a vise, compress the timing chain tensioner plunger.
58. Using a small pick, push back and hold the ratchet mechanism.
    Fig 55: Locating Ratchet Mechanism

    Courtesy of FORD MOTOR CO.
59. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Fig 56: Identifying Ratchet Arm
Courtesy of FORD MOTOR CO.
60. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
Fig 57: Holding Ratchet Assembly And Plunger
Courtesy of FORD MOTOR CO.
61. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
Fig 58: Locating Timing Chain Tensioner Bolts
Courtesy of FORD MOTOR CO.
NOTE: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
62. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.

    Tighten to 72 Nm (53 lb-ft).

Fig 59: Locating Camshaft Bolts
Courtesy of FORD MOTOR CO.
NOTE: 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.
63. 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.
64. 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 60: Locating Silicone Application Areas
Courtesy of FORD MOTOR CO.
65. 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 61: 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.
66. Using the special tool, install the crankshaft front oil seal.
Fig 62: Locating Crankshaft Front Oil Seal Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
67. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
Fig 63: Positioning Crankshaft Pulley
Courtesy of FORD MOTOR CO.
NOTE: 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.
68. 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 64: Aligning Crankshaft Pulley To Crankshaft
Courtesy of FORD MOTOR CO.
NOTE: 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.
NOTE: Do not reuse the crankshaft pulley bolt.
69. Install a new crankshaft pulley bolt. Using the special tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    1. Stage 1: Tighten to 100 Nm (74 lb-ft).
    2. Stage 2: Tighten an additional 90 degrees (1/4 turn).
Fig 65: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
70. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
Fig 66: Locating Bolt
Courtesy of FORD MOTOR CO.
71. Remove the special tool.
Fig 67: Locating Timing Cover Peg Special Tool
Courtesy of FORD MOTOR CO.
72. Remove the special tool.
Fig 68: Locating Camshaft Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
73. Turn the crankshaft clockwise 1 and 3/4 turns.
74. Install the special tool.
Fig 69: Locating Timing Cover Peg Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
Fig 70: Crankshaft Contacting Special Tool
Courtesy of FORD MOTOR CO.
75. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
76. 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 71: Checking Position Of Crankshaft Pulley
Courtesy of FORD MOTOR CO.
77. Install the special tool to check the position of the camshafts
    • If it is not possible to install the special tool, the engine valve timing must be corrected.
Fig 72: Checking Position Of Camshafts
Courtesy of FORD MOTOR CO.
78. Remove the special tool.
Fig 73: Locating Camshaft Special Tool
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.
79. Install a new CKP sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
Fig 74: 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.
80. Adjust the CKP sensor with the alignment tool.

    Tighten the 2 CKP bolts to 7 Nm (62 lb-in).

Fig 75: Locating Crankshaft Position (CKP) Sensor Bolts
Courtesy of FORD MOTOR CO.
81. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 76: Locating Bolt in Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
82. Remove the special tool.
    Fig 77: Locating Timing Cover Peg Special Tool

    Courtesy of FORD MOTOR CO.
83. Install the engine plug bolt.

    Tighten to 20 Nm (15 lb-ft).

    Fig 78: Locating Engine Plug Bolt

    Courtesy of FORD MOTOR CO.
NOTE: 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.
84. Clean the valve cover gasket surface with metal surface cleaner.
85. Apply silicone gasket and sealant to the locations shown.
    Fig 79: Locating Silicone Gasket Application Areas

    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.
Fig 80: Valve Cover Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
86. Install the valve cover.

    Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).

87. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
    1. Tighten the CHT sensor to 12 Nm (9 lb-ft).
    2. Tighten the spark plugs to 12 Nm (9 lb-ft).
    Fig 81: Locating Cylinder Head Temperature (CHT) Sensor And Spark Plugs

    Courtesy of FORD MOTOR CO.
NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
Fig 82: Locating Coil-On-Plugs, Bolts And Crankcase Vent Tube
Courtesy of FORD MOTOR CO.
88. Install the coil-on-plugs, bolts and the crankcase vent tube.

    Tighten to 8 Nm (71 lb-in).

89. Install the 3 engine cover studs.
    Fig 83: Locating Engine Cover Studs

    Courtesy of FORD MOTOR CO.
90. If equipped, install the block heater

    Tighten to 40 Nm (30 lb-ft).

    Fig 84: Locating Engine Cover Studs

    Courtesy of FORD MOTOR CO.
91. Install the coolant hoses.
    Fig 85: Locating Coolant Hoses

    Courtesy of FORD MOTOR CO.
NOTE: Clean the gasket mating surfaces with metal surface cleaner.
Fig 86: Locating Oil Filter Adapter
Courtesy of FORD MOTOR CO.
92. Install the oil filter adapter with a new gasket.

    Tighten to 25 Nm (18 lb-ft).

NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
Fig 87: Locating Crankcase Vent Oil Separator And Knock Sensor
Courtesy of FORD MOTOR CO.
93. Install the crankcase vent oil separator and the KS.
    1. Tighten the oil separator bolts to 10 Nm (89 lb-in).
    2. Tighten the KS to 20 Nm (15 lb-ft).
94. Install the coolant hose.
    Fig 88: Locating Coolant Hose

    Courtesy of FORD MOTOR CO.
NOTE: Clean and inspect the thermostat housing gasket. Replace if necessary.
Fig 89: Locating Thermostat Housing
Courtesy of FORD MOTOR CO.
95. Install the thermostat housing.

    Tighten to 10 Nm (89 lb-in).

96. Install the coolant hose.
    Fig 90: Locating Coolant Hose

    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.
Fig 91: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
97. Install the coolant pump and bolts.

    Tighten to 10 Nm (89 lb-in).

98. 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.
99. Position the engine control wiring harness on the engine and connect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 93: Locating Exhaust Gas Recirculation (EGR) Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
100. Connect the radio ignition interference capacitor electrical connector.
     Fig 94: Locating Radio Ignition Interference Capacitor Electrical Connector

     Courtesy of FORD MOTOR CO.
101. If equipped, connect the block heater electrical connector.
     Fig 95: Locating Block Heater Electrical Connector

     Courtesy of FORD MOTOR CO.
102. Connect the CHT sensor and install the rubber boot.
103. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
     Fig 96: Locating Coil-On-Plug And Camshaft Position (CMP) Sensor Electrical Connectors

     Courtesy of FORD MOTOR CO.
104. Install the accessory drive belt tensioner.

     Tighten to 25 Nm (18 lb-ft).

     Fig 97: Locating Accessory Drive Belt Tensioner

     Courtesy of FORD MOTOR CO.
105. Attach the engine wiring harness pin-type retainer.
     Fig 98: Locating Engine Wiring Harness Pin-Type Retainer

     Courtesy of FORD MOTOR CO.
106. Install the engine wiring harness connector bracket

     Tighten to 15 Nm (11 lb-ft)

     Fig 99: Locating Engine Wiring Harness Connector Bracket

     Courtesy of FORD MOTOR CO.
107. Connect the CKP sensor electrical connector.
     Fig 100: Locating CKP Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
108. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
NOTE: Special bolts are used for installation. Do not use standard bolts.
Fig 101: Flywheel Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
109. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following 3 stages:
     1. Stage 1: Tighten to 50 Nm (37 lb-ft).
     2. Stage 2: Tighten to 80 Nm (59 lb-ft).
     3. Stage 3: Tighten to 112 Nm (83 lb-ft).