Cylinder Heads and Intake Manifolds

Fig 1: Exploded View Of Cylinder Heads And Intake Manifolds Components

Courtesy of FORD MOTOR CO.

All engines 

NOTE: This procedure is for selecting bearings using a new crankshaft.
Fig 2: Locating Code On Crankshaft Flange And Code On Cylinder Block Rear Face
Courtesy of FORD MOTOR CO.
1. Select the crankshaft main bearings for each crankshaft journal.
   1. Read the code on the crankshaft flange.
   2. Read the code on the cylinder block rear face.
   • The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for main No. 2.
   • The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2 numbers for main No. 4.
2. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
   • For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
   Fig 3: View Of Block And Crankshaft Code 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.
Fig 4: Locating Crankshaft Main Bearings In Cylinder Block
Courtesy of FORD MOTOR CO.
3. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
4. Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the lower cylinder block.
   Fig 5: Locating Main Bearings In Lower Cylinder Block

   Courtesy of FORD MOTOR CO.
5. Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.
   Fig 6: Locating Crankshaft Thrust Bearing

   Courtesy of FORD MOTOR CO.
6. Install the crankshaft key.
   Fig 7: Locating Crankshaft Key

   Courtesy of FORD MOTOR CO.
7. Apply clean engine oil to the crankshaft main and rod bearing journals.
8. Position the crankshaft in the cylinder block.
   Fig 8: Positioning Crankshaft In Cylinder Block

   Courtesy of FORD MOTOR CO.
NOTE: The lower cylinder block must be installed and the bolts tightened within 4 minutes of applying the sealant.
NOTE: Clean and degrease both surfaces using metal surface prep before applying sealant.
Fig 9: Applying Gasket And Sealant To Cylinder Block With Specifications
Courtesy of FORD MOTOR CO.
9. Apply gasket and sealant to the cylinder block as shown in the illustration.
NOTE: Fasteners No. 5 through 8 are studs. Fasteners No. 18 through 22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 1 through 4, 17 are M8 x 1.25 mm x 96 mm (0.05 in x 3.75 in) bolts. Fasteners 9 through 12 are M10 x 1.5 mm x 106.8 mm (0.06 in x 4.20 in)/M8 x 1.25 mm x 21.5 mm (0.05 in x 0.84 in) studs. Fasteners 13 through 16 are M10 x 1.5 mm x 106.5 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position or engine damage can result.
Fig 10: Identifying Lower Cylinder Block Bolts And Studs Tightening Sequence
Courtesy of FORD MOTOR CO.
10. Position the lower cylinder block and install the new bolts and new studs.
    • Tighten the bolts and studs in the sequence shown in the illustration in 4 stages.
    • Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft).
    • Stage 2: Tighten fasteners 9 through 16 to 40 Nm (30 lb-ft).
    • Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees.
    • Stage 4: Tighten fasteners 17 through 22 to 25 Nm (18 lb-ft).
11. 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 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
    Fig 11: Measuring Crankshaft End Play Using Dial Indicator Gauge With Holding Fixture

    Courtesy of FORD MOTOR CO.
12. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal.
    Fig 12: Installing Rear Main Oil Seal Using Crankshaft Rear Main Oil Seal Installer And Crankshaft Rear Main Oil Seal Installer Bolts

    Courtesy of FORD MOTOR CO.
13. Install the engine-to-transaxle separator plate.
    Fig 13: Locating Engine-To-Transaxle Separator Plate

    Courtesy of FORD MOTOR CO.
14. Position the flexplate and install the bolts.
    • Tighten to 80 Nm (59 lb-ft).
    Fig 14: Locating Flexplate Bolts

    Courtesy of FORD MOTOR CO.
15. Mount the engine on an engine stand.
16. Using the chart, select the correct piston grade size for the cylinder bores.
    • Measure the cylinder block bore diameter.
    • Mark the outside of the block with the appropriate number(s) to identify bore grade size.
    • Choose the correct piston grade size for the cylinder bore.
    Fig 15: View Of Cylinder Block Bore Diameter Chart

    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 rings are positioned to specifications for installation. For additional information, refer to DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES - PISTON  in this service information.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
NOTE: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.
Fig 16: Installing Piston And Connecting Rod Assemblies Using Piston Ring Compressor And Connecting Rod Installer
Courtesy of FORD MOTOR CO.
17. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
Fig 17: Locating Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
18. Install the connecting rod caps and the new bolts.
    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
19. Install the oil separator cover, a new gasket and the bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 18: Locating Oil Separator Cover Bolts

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in the illustration, RH similar.
Fig 19: Identifying LH And RH Cylinder Heads Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
20. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown in the illustration in 6 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten to 90 Nm (66 lb-ft).
    • Stage 3: Loosen one full turn.
    • Stage 4: Tighten to 40 Nm (30 lb-ft).
    • Stage 5: Tighten 90 degrees.
    • Stage 6: Tighten 90 degrees.
21. Install the crankshaft pulley bolt and rotate the crankshaft keyway to the 11 o'clock position to locate Top Dead Center (TDC).
    Fig 20: Locating Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
NOTE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
22. Install the hydraulic lash adjusters.
    • Lubricate the hydraulic lash adjusters with clean engine oil.
23. Apply clean engine oil to the LH and RH camshaft roller followers.
NOTE: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE: RH shown in the illustration, LH similar.
Fig 21: Locating Camshaft Roller Followers
Courtesy of FORD MOTOR CO.
24. Install the LH and RH camshaft roller followers.
NOTE: LH shown in the illustration, RH similar.
Fig 22: Locating VCT System Oil Filter Screen
Courtesy of FORD MOTOR CO.
25. Install the new LH and RH oil filter screens in the intake camshafts.
26. Position the camshaft phaser and sprockets onto the intake camshafts.
    • Install the 3 bolts finger-tight.
27. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
    • Align the LH camshafts as shown in the illustration.
    Fig 23: Aligning LH Camshafts

    Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
Fig 24: Locating LH Camshaft Bearing Caps
Courtesy of FORD MOTOR CO.
28. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
    • Loosely install the bolts.
29. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
    • Loosely install the bolts.
    Fig 25: Locating LH Camshaft Bearing Thrust Caps

    Courtesy of FORD MOTOR CO.
NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
Fig 26: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
30. Tighten the LH camshaft bearing cap bolts in the sequence shown in the illustration in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
NOTE: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
Fig 27: Remove/Install LH Camshaft Phaser, Sprocket And Bolts
Courtesy of FORD MOTOR CO.
31. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
Fig 28: Locating Camshaft Oil Seal Retainer And Bolts
Courtesy of FORD MOTOR CO.
32. Install the camshaft oil seal retainer and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
Fig 29: Installing Camshaft Oil Seal Using Special Tools
Courtesy of FORD MOTOR CO.
33. Using the Power Steering Pump Pulley Installer, Camshaft Oil Seal Installer and the Camshaft Oil Seal Protector, install a new camshaft oil seal.
34. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
    • Align the RH camshafts as shown in the illustration.
    Fig 30: Identifying RH Camshafts Are In Neutral Position

    Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed or damage to the thrust caps can occur.
NOTE: Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil.
Fig 31: Locating Camshaft Bearing Caps
Courtesy of FORD MOTOR CO.
35. Install the camshaft bearing caps.
    • Loosely install the bolts.
NOTE: Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil.
Fig 32: Locating Camshaft Bearing Thrust Caps
Courtesy of FORD MOTOR CO.
36. Install the camshaft bearing thrust caps.
    • Loosely install the bolts.
NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
Fig 33: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
37. Tighten the RH camshaft bearing cap bolts in the sequence shown in the illustration in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
NOTE: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
Fig 34: Remove/Install RH Camshaft Phaser, Sprocket And Bolts
Courtesy of FORD MOTOR CO.
38. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
39. Position the oil pump and install the bolts.
    • Tighten in the sequence shown in the illustration to 10 Nm (89 lb-in).
    Fig 35: Identifying Oil Pump Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
40. Remove the crankshaft pulley bolt.
    Fig 36: Locating Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Failure to verify correct timing drive component alignment will result in severe engine damage.
Fig 37: Locating Crankshaft Sprocket With Timing Mark Facing Out
Courtesy of FORD MOTOR CO.
41. Install the crankshaft sprockets with the timing marks facing out. The timing mark on the LH and RH timing chains will be aligned to this mark during assembly.
NOTE: LH shown in the illustration, RH similar.
Fig 38: Positioning Chain Tensioner In Soft-Jawed Vise
Courtesy of FORD MOTOR CO.
42. Position the chain tensioner in a soft-jawed vise.
NOTE: LH shown in the illustration, RH similar.
Fig 39: Holding Chain Tensioner Ratchet Lock Mechanism Away From Ratchet Stem With Small Pick
Courtesy of FORD MOTOR CO.
43. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
NOTE: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
44. Slowly compress the timing chain tensioner.
45. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
    Fig 40: Retaining Tensioner Piston With 1.5 mm (0.06 in) Diameter Wire Or Paper Clip

    Courtesy of FORD MOTOR CO.
46. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
    1. Mark any link to use as the crankshaft timing mark.
    2. Starting with the crankshaft timing mark, count 29 links and mark the link.
    3. Continue counting to link 42 and mark the link.
    Fig 41: Identifying Timing Marks On Timing Chain

    Courtesy of FORD MOTOR CO.
47. Position the LH timing chain and guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
    Fig 42: Locating Bolts And LH Timing Chain Guide

    Courtesy of FORD MOTOR CO.
48. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 43: Identifying LH Timing Chain Tensioner Arm And Bolts

    Courtesy of FORD MOTOR CO.
49. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
    Fig 44: Locating Crankshaft Keyway Is In 3 O'Clock Position

    Courtesy of FORD MOTOR CO.
50. Verify that the RH camshafts are correctly positioned.
    Fig 45: Identifying RH Camshafts Are In Neutral Position

    Courtesy of FORD MOTOR CO.
51. Install the RH timing chain and chain guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
    Fig 46: Locating RH Timing Chain Guide And Bolts

    Courtesy of FORD MOTOR CO.
52. Install the RH timing chain tensioner and tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 47: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts

    Courtesy of FORD MOTOR CO.
53. Remove the LH and RH timing chain tensioner piston retaining wires.
54. Rotate the crankshaft counterclockwise 120 degrees to TDC.
NOTE: Failure to verify correct timing drive component alignment will result in severe engine damage.
Fig 48: Identifying Camshaft And Crankshaft Timing Marks Location
Courtesy of FORD MOTOR CO.
55. Verify the timing with the following steps.
    1. There should be 12 chain links between the camshaft timing marks.
    2. There should be 27 chain links between the camshaft and the crankshaft timing marks.
    3. There should be 30 chain links between the camshaft and the crankshaft timing marks.
56. Remove the crankshaft pulley bolt and washer.
    Fig 49: Locating Crankshaft Pulley Bolt And Washer

    Courtesy of FORD MOTOR CO.
NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" only (orange in color).
Fig 50: Identifying Ignition Pulse Wheel
Courtesy of FORD MOTOR CO.
57. Install the ignition pulse wheel.
NOTE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
Fig 51: Locating Spark Plugs
Courtesy of FORD MOTOR CO.
58. Install the LH and RH spark plugs.
    • Tighten to 15 Nm (133 lb-in).
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.
NOTE: Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder block-to-oil pan joint.
59. Use a plastic scraping tool to remove all traces of sealant.
    • Clean all sealing surfaces with metal surface prep and install new gaskets.
NOTE: Clean and degrease the sealing surfaces with metal surface prep before applying gasket and sealant.
NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
Fig 52: Locating Sealant Applying Area At Cylinder Block And Cylinder Head Mating Surfaces
Courtesy of FORD MOTOR CO.
60. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
NOTE: Fasteners 4 and 13 are stud bolts.
Fig 53: Identifying Engine Front Cover Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
61. Position the front cover and install the bolts and stud bolts.
    • Tighten in the sequence shown in the illustration to 25 Nm (18 lb-ft).
NOTE: Note the position of the alignment dowel on the engine front cover.
Fig 54: Locating LH VCT Connector And Bolts
Courtesy of FORD MOTOR CO.
62. Install the 2 bolts and the LH Variable Camshaft Timing (VCT) solenoid.
    • Tighten to 10 Nm (89 lb-in).
NOTE: Note the position of the alignment dowel on the engine front cover.
Fig 55: Locating RH VCT Connector And Bolts
Courtesy of FORD MOTOR CO.
63. Install the 2 bolts and the RH VCT solenoid.
    • Tighten to 10 Nm (89 lb-in).
NOTE: Clean all sealing surfaces with metal surface prep.
64. Apply clean engine oil to the seal lip and seal bore before installing the seal.
65. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
    Fig 56: Installing Crankshaft Front Seal Using Front Cover Oil Seal Installer And Crankshaft Vibration Damper Installer

    Courtesy of FORD MOTOR CO.
NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant.
NOTE: Sealing surfaces must be free of dirt and oil.
NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of sealant application.
Fig 57: Locating Sealant At End Of Keyway Slot
Courtesy of FORD MOTOR CO.
66. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
Fig 58: Installing Crankshaft Pulley Using Crankshaft Vibration Damper Installer
Courtesy of FORD MOTOR CO.
67. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
68. Install the bolt and washer. Tighten the bolt in 4 stages:
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 59: Locating Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
69. Install the belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 60: Locating Accessory Drive Belt Tensioner And Bolts

    Courtesy of FORD MOTOR CO.
70. Install the 8 nuts and the oil pan baffle.
    1. Tighten the 4 M6 oil pan baffle nuts in 2 stages.
       • Stage 1: Tighten to 5 Nm (44 lb-in).
       • Stage 2: Tighten an additional 45 degrees.
    2. Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages.
    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
    Fig 61: Identifying M6 And M8 Oil Pan Baffle Nuts

    Courtesy of FORD MOTOR CO.
71. Install a new O-ring seal on the oil pump screen and pickup tube.
    • Lubricate the O-ring seal with clean engine oil.
    Fig 62: Locating O-Ring Seal

    Courtesy of FORD MOTOR CO.
72. Install the oil pump screen and pickup tube.
    1. Position the oil pump screen and pickup tube.
    2. Install the 2 bolts and tighten to 10 Nm (89 lb-in).
    Fig 63: Identifying Bolts, Oil Pump Screen And Pickup Tube

    Courtesy of FORD MOTOR CO.
73. Install the new gasket in the LH valve cover in the following sequence.
    1. Install the gasket at waffle pads and then the corners.
    2. Install the gasket around bolt holes.
    3. Install the remaining part of the gasket.
    Fig 64: Identifying Valve Cover Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.
NOTE: Clean cylinder head and front cover surface and the cam seal retainer-to-cylinder head surface using metal surface prep before applying silicone gasket and sealant.
Fig 65: Locating Sealant At Cylinder Block To Front Cover Mating Surface And Cam Seal Retainer-To-Cylinder Head Joints
Courtesy of FORD MOTOR CO.
74. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints.
NOTE: Install a new valve cover gasket.
Fig 66: Identifying Valve Cover Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
75. Position the LH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown in the illustration to 10 Nm (89 lb-in).
76. Install the new gasket in the RH valve cover in the following sequence.
    1. Install the gasket at waffle pads and then the corners.
    2. Install the gasket around bolt holes.
    3. Install the remaining part of the gasket.
    Fig 67: Identifying Valve Cover Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.
NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.
Fig 68: Locating Silicone Gasket Sealant At Front Cover-To-Cylinder Head Joints
Courtesy of FORD MOTOR CO.
77. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
NOTE: Install a new valve cover gasket.
Fig 69: Identifying Valve Cover Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
78. Position the RH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown in the illustration to 10 Nm (89 lb-in).
79. If equipped, install the block heater.
    • Tighten to 21 Nm (15 lb-ft).
    Fig 70: Locating Block Heater

    Courtesy of FORD MOTOR CO.
NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Fig 71: Locating EOP Switch
Courtesy of FORD MOTOR CO.
80. Install the EOP switch.
    • Tighten to 14 Nm (124 lb-in).
81. Position the coolant pump housing and attach the coolant hose.
    • Tighten the clamp to 7 Nm (62 lb-in).
    Fig 72: Locating Coolant Hose Clamp

    Courtesy of FORD MOTOR CO.
82. Install the 5 coolant pump housing bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 73: Locating Coolant Pump Housing Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
Fig 74: Installing Camshaft Pulley Installer In Camshaft
Courtesy of FORD MOTOR CO.
83. Install the Camshaft Pulley Installer in the camshaft as shown in the illustration.
    • Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-485).
Fig 75: Installing Special Tools Flush With End Of Camshaft
Courtesy of FORD MOTOR CO.
84. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration.
    • Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
85. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
    Fig 76: Locating Coolant Pump Belt

    Courtesy of FORD MOTOR CO.
NOTE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.
86. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
87. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
    Fig 77: Locating O-Ring On Oil Level Indicator Tube

    Courtesy of FORD MOTOR CO.
88. Position the oil level indicator and tube and install the stud bolt.
    • Tighten to 9 Nm (80 lb-in).
    Fig 78: Locating Oil Level Indicator And Tube Stud Bolt

    Courtesy of FORD MOTOR CO.
89. Install the 3 bolts and the A/C compressor bracket.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 79: Locating Bolts And A/C Compressor Bracket

    Courtesy of FORD MOTOR CO.
90. Position the generator and install the bolt and 2 nuts.
    • Tighten to 47 Nm (35 lb-ft).
    Fig 80: Locating Generator Bolt And Nuts

    Courtesy of FORD MOTOR CO.
91. Install the A/C compressor and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 81: Locating A/C Compressor Bolts

    Courtesy of FORD MOTOR CO.
92. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
    Fig 82: Rotating Accessory Drive Belt Tensioner Counterclockwise

    Courtesy of FORD MOTOR CO.
93. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
    Fig 83: Locating RH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
94. Install a new gasket and the RH exhaust manifold and new nuts.
    • Tighten the nuts in 2 stages in the sequence shown in the illustration.
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 20 Nm (177 lb-in).
    Fig 84: Identifying RH Exhaust Manifold Nuts Tighten Sequence

    Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) 

95. Install a new gasket and the RH catalytic converter and the 3 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 85: Locating RH Catalytic Converter Nuts

    Courtesy of FORD MOTOR CO.
96. Install the 3 bolts and the RH heat shield.
    • Tighten to 10 Nm (89 lb-in).
    Fig 86: Locating RH Heat Shield Bolts

    Courtesy of FORD MOTOR CO.

    All engines 

NOTE: LH shown in the illustration, RH similar.
Fig 87: Locating Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
97. Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

    Install the 6 coil-on-plugs and the bolts.

    • Tighten to 6 Nm (53 lb-in).
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.
NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
Fig 88: Identifying Lower Intake Manifold Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
98. Position the lower intake manifold and install the 8 bolts.
    • Tighten in the sequence shown in the illustration to 10 Nm (89 lb-in).
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.
Fig 89: Locating Fuel Injector O-Rings
Courtesy of FORD MOTOR CO.
99. 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.
100. Install the 4 bolts and the fuel rail and injectors assembly.
     • Tighten to 10 Nm (89 lb-in).
     Fig 90: Locating Fuel Rail And Injectors Assembly Bolts

     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.
NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
Fig 91: Identifying Upper Intake Manifold Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
101. Position the upper intake manifold and install the 7 bolts.
     • Tighten the bolts in 2 stages in the sequence shown in the illustration.
     • Stage 1: Tighten to 10 Nm (89 lb-in).
     • Stage 2: Tighten an additional 45 degrees.
102. Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown in the illustration), then tighten all the bolts.
     • Tighten to 10 Nm (89 lb-in).
     Fig 92: Locating Upper Intake Manifold Bracket Lower Bolt

     Courtesy of FORD MOTOR CO.
103. Connect the 3 LH coil-on-plug electrical connectors.
     • Attach the 2 wiring harness retainers.
     Fig 93: Locating LH Coil-On-Plug Electrical Connectors

     Courtesy of FORD MOTOR CO.
104. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer to the oil indicator tube.
     Fig 94: Locating Engine Oil Pressure Switch Electrical Connector And Wiring Retainer Of Oil Indicator Tube

     Courtesy of FORD MOTOR CO.
105. Install the radio interference capacitor and the nut.
     • Tighten to 6 Nm (53 lb-in).
     Fig 95: Locating Radio Frequency Interference Capacitor Nut

     Courtesy of FORD MOTOR CO.
106. Connect the LH VCT electrical connector.
     Fig 96: Locating LH VCT Electrical Connector

     Courtesy of FORD MOTOR CO.
107. Connect the fuel injector wiring harness electrical connector and attach the wiring harness retainer.
     Fig 97: Locating Fuel Injector Wiring Harness Electrical Connector And Wiring Harness Retainer

     Courtesy of FORD MOTOR CO.
108. Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness retainer from the engine front cover stud bolt.
     Fig 98: Locating Camshaft Position Sensor Electrical Connectors, Wiring Harness Retainer And Engine Front Cover Stud Bolt

     Courtesy of FORD MOTOR CO.
109. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring harness retainers.
     Fig 99: Locating Crankshaft Position Sensor Electrical Connector And Wiring Harness Retainers

     Courtesy of FORD MOTOR CO.
110. Connect the RH VCT electrical connector and attach the wiring harness retainer to the valve cover stud bolt.
     Fig 100: Locating RH Variable Camshaft Timing Electrical Connector And Wiring Harness Retainer

     Courtesy of FORD MOTOR CO.
111. Connect the RH coil-on-plug electrical connectors.
     • Attach the 2 wiring harness retainers.
     Fig 101: Locating RH Coil-On-Plug Electrical Connectors

     Courtesy of FORD MOTOR CO.
112. Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer.
     Fig 102: Locating Manifold Absolute Pressure Electrical Connector And Wiring Retainer

     Courtesy of FORD MOTOR CO.
113. Attach the wiring harness retainer to the upper intake manifold.
     Fig 103: Locating Wiring Harness Retainer Of Upper Intake Manifold

     Courtesy of FORD MOTOR CO.
114. Connect the PCV valve electrical connector.
     Fig 104: Locating PCV Valve Electrical Connector

     Courtesy of FORD MOTOR CO.
115. Connect the EGR regulator electrical connector and attach the wiring retainer.
     Fig 105: Locating EGR Regulator Electrical Connector And Wiring Retainer

     Courtesy of FORD MOTOR CO.
116. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
     Fig 106: Locating Evaporative Emission Canister Purge Valve Electrical Connector

     Courtesy of FORD MOTOR CO.
117. Connect the electronic throttle control electrical connector.
     Fig 107: Locating Electronic Throttle Control Electrical Connector

     Courtesy of FORD MOTOR CO.
118. Connect the 3 engine wiring connectors.
     • Connect the engine block Knock Sensor (KS) electrical connector.
     • Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
     • Connect the cylinder head KS electrical connector.
     Fig 108: Locating Engine Block Knock Sensor Electrical Connector And Cylinder Head KS Electrical Connector

     Courtesy of FORD MOTOR CO.
119. Position the B+ wiring harness and attach the 2 harness retainers to the valve cover stud bolts.
     Fig 109: Locating B+ Wiring Harness Retainers Of Valve Cover Stud Bolts

     Courtesy of FORD MOTOR CO.
120. Install the B+ wire and nut on the generator.
     • Tighten to 8 Nm (71 lb-in).
     Fig 110: Locating Generator B+ Wire Nut

     Courtesy of FORD MOTOR CO.
121. Connect the generator electrical connector.
     Fig 111: Locating Generator Electrical Connector

     Courtesy of FORD MOTOR CO.
122. Connect the A/C compressor clutch electrical connector.
     Fig 112: Locating A/C Compressor Clutch Electrical Connector

     Courtesy of FORD MOTOR CO.
NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.
Fig 113: Locating Lower Half Of Engine Lifting Bracket Set
Courtesy of FORD MOTOR CO.
123. Install the lower half of the Engine Lifting Bracket Set.
124. Install the upper half of the Engine Lifting Bracket Set.
     Fig 114: Locating Upper Half Of Engine Lifting Bracket Set

     Courtesy of FORD MOTOR CO.
125. Install the Engine Lifting Bracket.
     Fig 115: Identifying Engine Lifting Bracket

     Courtesy of FORD MOTOR CO.
126. Install the Engine Lifting Bracket and the Universal Adapter Bracket.
     Fig 116: Identifying Engine Lifting Bracket And Universal Adapter Bracket

     Courtesy of FORD MOTOR CO.
127. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, remove the engine from the engine stand.
     Fig 117: Removing Engine From Engine Stand Using Special Tools

     Courtesy of FORD MOTOR CO.