Intake Manifold

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Exploded View Of Intake Manifold

Courtesy of FORD MOTOR CO.

PART NUMBER REFERENCE

Item	Part Number	Description
1	9288	Fuel supply tube
2	8K556	Coolant outlet
3	9D475	EGR valve
4	9E926	Electronic throttle body
5	6051	Cylinder head gasket
6	6010	Cylinder block
7	12A699	Knock Sensor (KS)
8	9424	Intake manifold
9	9439	Intake manifold gasket
10	8A582	Coolant hose
11	6049	Cylinder head
12	9F593	Fuel injector (4 required)
13	9H487	Fuel rail

NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage may occur.

NOTE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

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.

Install the 4 oil squirters.
- Tighten to 4 Nm (35 lb-in).
  
  Fig 2: Locating Oil Squirters
  Courtesy of FORD MOTOR CO.
Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.

Fig 3: Measuring Crankshaft Main Bearing Journal Diameters
Courtesy of FORD MOTOR CO.
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 4: Locating Main Bearing Beam
Courtesy of FORD MOTOR CO.
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 5: Identifying Main Bearing Beam Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Measure each crankshaft block main bearing bore diameter.
- Remove the bolts and the main bearing beam.
- Discard the main bearing beam bolts.
  
  Fig 6: Identifying Crankshaft Block Main Bearing Bore Diameter
  Courtesy of FORD MOTOR CO.
Using the chart, select the crankshaft main bearings.

Fig 7: Crankshaft Main Bearings 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.

Using the original connecting rod cap bolts, install the connecting caps and bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
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 8: Measuring Connecting Rod Large End Bore
  Courtesy of FORD MOTOR CO.
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 9: Measuring Crankshaft Connecting Rod Bearing Journal Diameters
Courtesy of FORD MOTOR CO.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

Fig 10: Connecting Rod Bearings 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.

Fig 11: Locating Upper Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

Fig 12: Locating Main Bearings

Courtesy of FORD MOTOR CO.

Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.

Fig 13: Locating Crankshaft Gear
Courtesy of FORD MOTOR CO.
Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.

Fig 14: Locating Main Bearing Beam Side Fit Surfaces
Courtesy of FORD MOTOR CO.
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 15: Locating Main Bearing Beam
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.

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 16: Identifying Main Bearing Beam Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
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 17: 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.

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 18: Identifying Piston Ring Compressor And Connecting Rod Installer
  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.

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 19: Identifying Connecting Rod Cap Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
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 20: Installing 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 positions.

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.

Install the adjustment shims in their original positions on the seat faces of the balancer unit.
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 21: Locating Balancer Unit And Shafts Reference Mark
Courtesy of FORD MOTOR CO.
Install the balancer unit bolts.
- Tighten in the sequence shown in 2 stages.
  - Stage 1: Tighten to 25 Nm (18 lb-ft).
  - Stage 2: Tighten to 50 Nm (37 lb-ft).
    
    Fig 22: Identifying Balancer Unit Bolts Tightening Sequence
    Courtesy of FORD MOTOR CO.
Remove the Crankshaft TDC Timing Peg.

Fig 23: Installing Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
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.
- Remove the Crankshaft TDC Timing Peg.
  
  Fig 24: Installing 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.

Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
- 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.
- 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.
- Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
- If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. For additional information, refer to BALANCE SHAFT BACKLASH .
  
  Fig 25: Measuring Gear Backlash
  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.

Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).

NOTE: The Crankshaft TDC Timing Peg 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.

Fig 26: Installing Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Install the Crankshaft TDC Timing Peg.

NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.

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 (177 lb-in).
  
  Fig 27: Identifying Oil Pump Assembly Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install a new oil pump pickup tube gasket and the pickup tube.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 28: Identifying Oil Pump Pickup Tube
  Courtesy of FORD MOTOR CO.
Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.

Fig 29: Installing Crankshaft Rear Main Oil Seal
Courtesy of FORD MOTOR CO.
Tighten the crankshaft rear oil seal retainer bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 30: Identifying Crankshaft Rear Oil Seal Retainer Plate 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 to remove traces of sealant.

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 prep. 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.

Fig 31: Locating Oil Pan Bolts

Courtesy of FORD MOTOR CO.

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.
Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.

Fig 32: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block
Courtesy of FORD MOTOR CO.
Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 33: Identifying Oil Pan Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the cylinder head alignment dowels.
- Dowels must be fully seated in the cylinder block.
  
  Fig 34: Locating Cylinder Head Alignment Dowels
  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.

Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
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.
Apply silicone gasket and sealant to the locations shown.

Fig 35: Identifying Silicone Gasket And Sealant Application Points
Courtesy of FORD MOTOR CO.
Install a new head gasket.

Fig 36: 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.

Install the cylinder head and 10 new 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 (133 lb-in).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Turn 90 degrees.
- Stage 5: Turn an additional 90 degrees.
  
  Fig 37: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

Install the valve tappets.

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.

Install the camshafts and bearing caps in their original locations and orientation. Tighten the bearing caps 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 (142 lb-in).
  
  Fig 38: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the Variable Camshaft Timing (VCT) system oil filter and the plug in the intake camshaft thrust cap.
- Tighten to 17 Nm (150 lb-in).
  
  Fig 39: Locating Plug And VCT System Oil Filter
  Courtesy of FORD MOTOR CO.
Install the VCT solenoid and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 40: Locating Bolt And Variable Camshaft Timing Solenoid
  Courtesy of FORD MOTOR CO.

NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.

Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
- The crankshaft sprocket flange must be facing away from the engine block.
  
  Fig 41: Locating Crankshaft Sprocket
  Courtesy of FORD MOTOR CO.
Install the oil pump chain, sprocket and bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 42: Locating Oil Pump Chain, Sprocket And Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump chain tensioner shoulder bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 43: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 44: Locating Oil Pump Drive Chain Tensioner, Bolt And Tensioner Spring
  Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Fig 45: Identifying Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.

Fig 46: Locating Camshaft Sprockets And Bolts
Courtesy of FORD MOTOR CO.
Install the LH timing chain guide and the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 47: Locating Timing Chain Guide Bolts
  Courtesy of FORD MOTOR CO.
Install the timing chain.

Fig 48: Locating Timing Chain
Courtesy of FORD MOTOR CO.
Install the RH timing chain guide.

Fig 49: Locating Timing Chain Guide
Courtesy of FORD MOTOR CO.

NOTE: If the timing chain tensioner 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 50: Compressing Timing Chain Tensioner Plunger

Courtesy of FORD MOTOR CO.

Using the edge of a vise, compress the timing chain tensioner plunger.
Using a small pick, push back and hold the ratchet mechanism.

Fig 51: Pushing Back And Hold Ratchet Mechanism
Courtesy of FORD MOTOR CO.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 52: Pushing Ratchet Arm Back Into Tensioner Housing
Courtesy of FORD MOTOR CO.
Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

Fig 53: Installing Paper Clip Into Hole In Tensioner Housing
Courtesy of FORD MOTOR CO.
Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 54: Locating Timing Chain Tensioner And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
- Tighten to 72 Nm (53 lb-ft).
  
  Fig 55: 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.

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.

Fig 56: Applying Silicone Gasket And Sealant On Engine Front Cover

Courtesy of FORD MOTOR CO.

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.
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 57: Identifying Tightening Sequence Of Engine Front Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.

Fig 58: Installing Crankshaft Front Oil Seal Using Special Tool

Courtesy of FORD MOTOR CO.

Using the Camshaft Front Oil Seal Installer, install a new crankshaft front oil seal.

NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

Fig 59: Positioning Crankshaft Pulley Hole At 6 O'Clock Position

Courtesy of FORD MOTOR CO.

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.

NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Fig 60: Locating Crankshaft Pulley Hole Bolt

Courtesy of FORD MOTOR CO.

Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.

NOTE: The crankshaft must remain in the Top Dead Center (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 Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool 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 61: Locating Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.
Remove the 6 mm x 18 mm bolt.

Fig 62: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the Crankshaft TDC Timing Peg.

Fig 63: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Remove the Camshaft Alignment Plate.

Fig 64: Identifying Camshaft Alignment Plate
Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise one and three-fourths turns.
Install the Crankshaft TDC Timing Peg.

Fig 65: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

Fig 66: Installing Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.

NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm x 18 mm 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 67: Locating Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.
Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
  
  Fig 68: Identifying Camshaft Alignment Plate
  Courtesy of FORD MOTOR CO.
Remove the Camshaft Alignment Plate.

Fig 69: Identifying Camshaft Alignment Plate
Courtesy of FORD MOTOR CO.
Install the Crankshaft Position (CKP) sensor and the 2 bolts.
- Do not tighten the bolts at this time.
  
  Fig 70: Locating CKP Sensor And Bolts
  Courtesy of FORD MOTOR CO.
Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
- Tighten the 2 CKP sensor bolts to 7 Nm (62 lb-in).
  
  Fig 71: Identifying Crankshaft Sensor Aligner
  Courtesy of FORD MOTOR CO.
Remove the 6 mm x 18 mm bolt.

Fig 72: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the Crankshaft TDC Timing Peg.

Fig 73: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 74: 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.

Clean the valve cover gasket surface with metal surface cleaner.
Apply silicone gasket and sealant to the locations shown.

Fig 75: Locating Silicone Gasket And Sealant Applying Locations
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.

Install the valve cover.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 76: Identifying Valve Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the 4 coil-on-plugs and the 4 bolts.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 77: Locating Bolts And Coil-On-Plugs
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.

Fig 78: Locating Oil Level Indicator

Courtesy of FORD MOTOR CO.

Install the oil level indicator.
If equipped, install the block heater.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 79: Locating Block Heater
  Courtesy of FORD MOTOR CO.
Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 80: Locating Bolts And Crankcase Vent Oil Separator
  Courtesy of FORD MOTOR CO.

NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.

Install the KS and the bolt.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 81: Identifying Bolt And Knock Sensor
  Courtesy of FORD MOTOR CO.
Install the 2 coolant hoses.

Fig 82: Locating Coolant Hoses
Courtesy of FORD MOTOR CO.
Install the coolant hose.

Fig 83: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
Install the coolant hose.

Fig 84: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
Install the EGR tube.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 85: Locating EGR Tube
  Courtesy of FORD MOTOR CO.

NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Fig 86: Locating Crankcase Vent Oil Separator Tube

Courtesy of FORD MOTOR CO.

Position the intake manifold and connect the crankcase vent oil separator tube.

NOTE: Inspect and install new intake manifold gaskets, if necessary.

Install the intake manifold gaskets, intake manifold and the 8 bolts.
- Tighten to 18 Nm (159 lb-in).
  
  Fig 87: Locating Bolts And Intake Manifold
  Courtesy of FORD MOTOR CO.

NOTE: 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.

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 88: Locating Fuel Injector O-Ring Seals
  Courtesy of FORD MOTOR CO.
Install the fuel rail with the fuel injectors as an assembly and the 2 stud bolts.
- Tighten to 23 Nm (17 lb-ft).
  
  Fig 89: Locating Stud Bolts, Fuel Rail And Fuel Injectors
  Courtesy of FORD MOTOR CO.
Install the radio capacitor and nut.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 90: Locating Nut And Radio Capacitor
  Courtesy of FORD MOTOR CO.
Install the fuel rail insulator.

Fig 91: Locating Fuel Rail Insulator
Courtesy of FORD MOTOR CO.
Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.

Fig 92: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the radio capacitor electrical connector.

Fig 93: Locating Radio Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.

Fig 94: Identifying Cylinder Head Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 4 coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.

Fig 95: Locating Coil-On-Plugs And Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Attach all wiring harness retainers to the intake manifold.
Connect the KS and attach the 2 wiring harness retainers.

Fig 96: Locating Knock Sensor And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the EGR valve electrical connector.

Fig 97: Locating EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.

Fig 98: Locating Electronic Throttle Control And Evaporative Emission Canister Purge Valve Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.

Fig 99: Locating Manifold Absolute Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainers to the LH side valve cover stud bolts.

Fig 100: Locating Wiring Harness Retainers And LH Side Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
Connect the crankcase vent hose to the valve cover.

Fig 101: Locating Crankcase Vent Hose
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainers to the RH side valve cover stud bolts.

Fig 102: Locating Wiring Harness Retainers And RH Side Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
Connect the VCT electrical connector.

Fig 103: Locating Variable Camshaft Timing Electrical Connector
Courtesy of FORD MOTOR CO.
If removed, install the capacitor and bolt.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 104: Locating Bolt And Capacitor
  Courtesy of FORD MOTOR CO.

NOTE: Clean the gasket mating surfaces with metal surface prep.

Install the oil filter adapter with a new gasket.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 105: Locating Bolts And Oil Filter Adapter
  Courtesy of FORD MOTOR CO.
Connect the Engine Oil Pressure (EOP) switch electrical connector.

Fig 106: Locating Engine Oil Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the coolant tube retainer to the intake manifold.

Fig 107: Locating Coolant Tube Retainer
Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.

Install the thermostat housing and bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 108: Locating Bolts And Thermostat Housing Assembly
  Courtesy of FORD MOTOR CO.

NOTE: Clean the coolant pump mating surface with metal surface prep.

NOTE: Lubricate the coolant pump O-ring with clean engine coolant.

Install the coolant pump and bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 109: Locating Bolts And Coolant Pump
  Courtesy of FORD MOTOR CO.
Install the 3 coolant pump pulley and bolts.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 110: Locating Bolts And Coolant Pump Pulley
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley and bracket and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 111: Locating Bolts And Accessory Drive Belt Idler Pulley Bracket
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 112: Locating Bolt And Accessory Drive Belt Idler Pulley
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 113: Locating Bolts And Accessory Drive Belt Tensioner
  Courtesy of FORD MOTOR CO.
Install 7 new exhaust manifold studs in the cylinder head.
- Tighten to 17 Nm (150 lb-in).
  
  Fig 114: Locating Exhaust Manifold Studs
  Courtesy of FORD MOTOR CO.
Install the new exhaust manifold gasket on the engine.

NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

NOTE: Make sure to tighten the nuts in the sequence shown in 2 stages.

Position the exhaust manifold and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages:
- Stage 1: Tighten to 48 Nm (35 lb-ft).
- Stage 2: Tighten to 48 Nm (35 lb-ft).
  
  Fig 115: Identifying Exhaust Manifold Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the exhaust manifold heat shield and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 116: Locating Exhaust Manifold Heat Shield Bolts And Heat Shield
  Courtesy of FORD MOTOR CO.
Connect the Heated Oxygen Sensor (HO2S) electrical connector.

Fig 117: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
Install the generator, 2 nuts and 1 bolt.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 118: Locating Nuts, Bolt And Generator
  Courtesy of FORD MOTOR CO.
Connect the generator electrical connection and install the nut.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 119: Locating Nut And Generator Wiring Harness
  Courtesy of FORD MOTOR CO.
Connect the generator electrical connection and attach the 2 wiring harness retainers.

Fig 120: Locating Safety Belt Bolt
Courtesy of FORD MOTOR CO.
Connect the CKP sensor electrical connector.
- Attach the wiring harness-to-engine retainer.
  
  Fig 121: Locating Crankshaft Position Sensor Electrical Connector
  Courtesy of FORD MOTOR CO.
Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
Vehicles with automatic transaxle
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 122: Identifying Flexplate Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
  
  Vehicles with manual transaxle
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 123: Identifying Flywheel Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Lubricate the transaxle input shaft pilot bearing with front axle grease.

Fig 124: Locating Transaxle Input Shaft Pilot Bearing
Courtesy of FORD MOTOR CO.

NOTE: Use a clutch disc aligner (such as OTC® Clutch Alignment Tool Set 4528 or equivalent).

Fig 125: Positioning Clutch Disc On Flywheel

Courtesy of FORD MOTOR CO.

Using a suitable clutch disc aligner, position the clutch disc on the flywheel.

NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.

Position the clutch pressure plate and install the bolts.
- Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.