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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 422 (Engine - 3.9L) >> Installation >> Cylinder Heads >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean and dry.
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.
    CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.
    CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
  1. To install individual components, carry out only the listed steps.
    INDIVIDUAL COMPONENTS REMOVING STEPS

    Component Steps
    LH cylinder head 1-3, 15-65, 72-147
    RH cylinder head 4-14, 23-59, 66-147
  2. Illustration 1 of 20. Install the components in the order indicated in the following illustration and table. See Fig 1.
    Fig 1: Installing Order Of Cylinder Head Components
    G03201300Courtesy of FORD MOTOR CO.
  3. Illustration 2 of 20. Install the components in the order indicated in the following illustration and table. See Fig 2.
    Fig 2: Installing Order Of Intake And Exhaust Camshaft Components
    G03201301Courtesy of FORD MOTOR CO.
  4. NOTE: The following illustration is for reference only. Installation notes must be followed for installing timing drive components.
    Fig 3: Installing Order Of Timing Chain, Camshaft Sprocket And VCT Unit Components
    G03201302Courtesy of FORD MOTOR CO.
  5. Illustration 3 of 20. Install the components in the order indicated in the following illustration and table. See Fig 3.
  6. NOTE: The following illustration is for reference only. Installation notes must be followed for installing timing drive components.
    Fig 4: Installing Order Of Timing Chain Components
    G03201303Courtesy of FORD MOTOR CO.
  7. Illustration 4 of 20. Install the components in the order indicated in the following illustration and table. See Fig 4.
  8. NOTE: The following illustration is for reference only. Installation notes must be followed for installing timing drive components.
    Fig 5: Installing Order Of Timing Chain Tensioner Components
    G03201304Courtesy of FORD MOTOR CO.
  9. Illustration 5 of 20. Install the components in the order indicated in the following illustration and table. See Fig 5.
  10. NOTE: The following illustration is for reference only. Installation notes must be followed for installing timing drive components.
    Fig 6: Installing Order Of VCT Bush Carrier Components
    G03201305Courtesy of FORD MOTOR CO.
  11. Illustration 6 of 20. Install the components in the order indicated in the following illustration and table. See Fig 6.
  12. Illustration 7 of 20. Install the components in the order indicated in the following illustration and table. See Fig 7.
    Fig 7: Installing Order Of Engine Front Cover Components
    G03201306Courtesy of FORD MOTOR CO.
  13. Illustration 8 of 20. Install the components in the order indicated in the following illustration and table. See Fig 8.
    Fig 8: Installing Order Of LH Exhaust Manifold Components
    G03201307Courtesy of FORD MOTOR CO.
  14. Illustration 9 of 20. Install the components in the order indicated in the following illustration and table. See Fig 9.
    Fig 9: Installing Order Of RH Exhaust Manifold Components
    G03201308Courtesy of FORD MOTOR CO.
  15. Illustration 10 of 20. Install the components in the order indicated in the following illustration and table. See Fig 10.
    Fig 10: Installing Order Of Valve Cover Components
    G03201309Courtesy of FORD MOTOR CO.
  16. Illustration 11 of 20. Install the components in the order indicated in the following illustration and table. See Fig 11.
    Fig 11: Installing Order Of Intake Manifold And Throttle Body Components
    G03201310Courtesy of FORD MOTOR CO.
  17. Illustration 12 of 20. Install the components in the order indicated in the following illustration and table. See Fig 12.
    Fig 12: Installing Order Of Coolant By Pass Housing Components
    G03201311Courtesy of FORD MOTOR CO.
  18. Illustration 13 of 20. Install the components in the order indicated in the following illustration and table. See Fig 13.
    Fig 13: Installing Order Of EGR System Module, Engine Cover Support Bracket And RH Ignition Coil Components
    G03201312Courtesy of FORD MOTOR CO.
  19. Illustration 14 of 20. Install the components in the order indicated in the following illustration and table. See Fig 14.
    Fig 14: Installing Order Of LH Ignition Coil Components
    G03201313Courtesy of FORD MOTOR CO.
  20. Illustration 15 of 20. Install the components in the order indicated in the following illustration and table. See Fig 15.
    Fig 15: Installing Order Of Engine Cover Support Bracket, Oil Level Indicator Tube And Vacuum Hose Components
    G03201314Courtesy of FORD MOTOR CO.
  21. Illustration 16 of 20. Install the components in the order indicated in the following illustration and table. See Fig 16.
    Fig 16: Installing Order Of Different Electrical Connector
    G03201315Courtesy of FORD MOTOR CO.
  22. Illustration 17 of 20. Install the components in the order indicated in the following illustration and table. See Fig 17.
    Fig 17: Installing Order Of Power Steering Pump And Coil Cover Components
    G03201316Courtesy of FORD MOTOR CO.
  23. Illustration 18 of 20. Install the components in the order indicated in the following illustration and table. See Fig 18.
    Fig 18: Installing Order Of A/C Compressor Components
    G03201317Courtesy of FORD MOTOR CO.
  24. Illustration 19 of 20. Install the components in the order indicated in the following illustration and table. See Fig 19.
    Fig 19: Installing Order Of Crank Shaft Pulley And Accessory Drive Belt Components
    G03201318Courtesy of FORD MOTOR CO.
  25. Illustration 20 of 20. Install the components in the order indicated in the following illustration and table. See Fig 20.
    Fig 20: Installing Order Of Oil Filter And Oil Cooler Components
    G03201319Courtesy of FORD MOTOR CO.
  26. Remove the engine from the engine stand.
  27. Install the engine. For additional information, refer to ENGINE  under INSTALLATION in this section.

Items 1-6: RH and LH Cylinder Head Installation Note 

  1. Lightly oil the new cylinder head bolts and allow to drain for a few minutes before installing.
  2. Position the cylinder heads.
    • Install new gaskets.
      Fig 21: Installing New Gaskets
      G03201320Courtesy of FORD MOTOR CO.
  3. NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. Always use new bolts.
  4. Install and tighten the RH head bolts in four stages in the sequence shown. See Fig 22.
    • Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft).
    • Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees.
    • Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
      Fig 22: Identifying RH Head Bolts Tightening Sequence
      G03201321Courtesy of FORD MOTOR CO.
  5. Install and tighten the bolts in two stages.
    1. Tighten to 20 N.m (15 lb-ft).
    2. Tighten an additional 90 degrees.
    Fig 23: Installing Cylinder Head End Bolts
    G03201322Courtesy of FORD MOTOR CO.
  6. Install and tighten the LH head bolts in four stages in the sequence shown. See Fig 24.
    • Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft).
    • Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees.
    • Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
    • Fig 24: Identifying LH Head Bolts Tightening Sequence
      G03201323Courtesy of FORD MOTOR CO.
  7. Install and tighten the bolts in two stages.
    • Tighten to 20 N.m (15 lb-ft).
    • Tighten an additional 90 degrees.
    Fig 25: Installing Cylinder Head End Bolts
    G03201324Courtesy of FORD MOTOR CO.

Items 7-22: RH and LH Camshaft Installation Note 

    NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.
    NOTE: LH camshafts shown, RH camshafts similar.
    Fig 26: Positioning Camshafts On Camshaft Journals
    G03201325Courtesy of FORD MOTOR CO.
  1. Position the camshafts on the camshaft journals.
  2. CAUTION: Install the camshaft bearing caps. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
  3. Install the RH camshaft bearing caps.
    • Position the bearing caps.
    • Install the bolts. Tighten the bolts in three stages in the sequence shown. See Fig 27.
      • Stage 1: Hand-tighten.
      • Stage 2: Tighten to 6 N.m (53 lb-in).
      • Stage 3: Tighten an additional 90 degrees.
    • Fig 27: Identifying RH Camshaft Bearing Caps Bolts Tightening Sequence
      G03201326Courtesy of FORD MOTOR CO.
  4. CAUTION: Install the camshaft bearing caps. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
    Fig 28: Identifying LH Camshaft Bearing Caps Bolts Tightening Sequence
    G03201327Courtesy of FORD MOTOR CO.
  5. Install the LH camshaft bearing caps.
    • Position the bearing caps.
    • Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown. See Fig 28.
      • Stage 1: Hand-tighten.
      • Stage 2: Tighten to 6 N.m (53 lb-in).
      • Stage 3: Tighten an additional 90 degrees.
  6. CAUTION: If any components are installed new, the engine must be reshimmed or engine damage can occur.
    Fig 29: Checking Tappet And Shim Clearances Using Feeler Gauge
    G03201328Courtesy of FORD MOTOR CO.
  7. Using a feeler gauge, confirm that the tappet and shim clearances are within specification. For additional information, refer to VALVE CLEARANCE CHECK  in this section.
  8. If tappet and shim clearances are not within specification, adjust the clearance. For additional information, refer to VALVE CLEARANCE ADJUSTMENT  in this section.

Items 24-30, : LH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note 

  1. Install the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 30: Installing LH VCT Unit
    G03201329Courtesy of FORD MOTOR CO.
  2. Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.
    Fig 31: Installing LH VCT Unit And Exhaust Camshaft Sprocket Bolts Finger-Tight Using New Bolts
    G03201330Courtesy of FORD MOTOR CO.
  3. Remove the locking pin from the LH secondary timing chain tensioner.
    Fig 32: Removing Locking Pin From LH Secondary Timing Chain Tensioner
    G03201331Courtesy of FORD MOTOR CO.

Items 31-37: RH Variable Camshaft Timing (VCT) Unit, Exhaust Camshaft Sprocket and Secondary Timing Chain Installation Note 

  1. Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 33: Installing RH VCT Unit
    G03201332Courtesy of FORD MOTOR CO.
  2. Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.
    Fig 34: Installing RH VCT Unit And Exhaust Camshaft Sprocket Bolts Finger-Tight Using New Bolts
    G03201333Courtesy of FORD MOTOR CO.
  3. Remove the locking pin from the RH secondary timing chain tensioner.
    Fig 35: Removing Locking Pin From RH Secondary Timing Chain Tensioner
    G03201334Courtesy of FORD MOTOR CO.

Items 38-51: Timing Drive Components Installation Note 

  1. Reset the timing chain tensioners.
    1. Hold the lever toward the tensioner piston.
    2. Using finger pressure, compress the tensioner.
    3. Push the lever down and install a drill rod to lock the piston.
    Fig 36: Resetting Timing Chain Tensioners
    G03201335Courtesy of FORD MOTOR CO.
  2. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
    Fig 37: Installing Special Tool On LH Head
    G03201336Courtesy of FORD MOTOR CO.
  3. Install the special tool on the LH head.
  4. Position the LH timing chain and crankshaft gear.
    • Position the timing chain over the LH intake camshaft sprocket.
    • Position the crankshaft gear in the timing chain.
    Fig 38: Positioning LH Timing Chain And Crankshaft Gear
    G03201337Courtesy of FORD MOTOR CO.
  5. Install the LH timing chain guide.
    Fig 39: Installing LH Timing Chain Guide
    G03201338Courtesy of FORD MOTOR CO.
  6. Install the LH timing chain tensioner arm.
    Fig 40: Installing LH Timing Chain Tensioner Arm
    G03201339Courtesy of FORD MOTOR CO.
  7. Install the LH timing chain tensioner.
    1. Install the timing chain tensioner and bolts.
    2. Remove the drill rod.
    Fig 41: Installing LH Timing Chain Tensioner
    G03201340Courtesy of FORD MOTOR CO.
  8. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.
    CAUTION: Using the special tool, apply 10 N.m (89 lb-in) counterclockwise to the LH exhaust camshaft sprocket.
  9. Tighten the LH exhaust camshaft sprocket and variable camshaft timing (VCT) unit bolts in two stages:
    • Stage 1: Tighten to 35 N.m (26 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 42: Tightening LH Exhaust Camshaft Sprocket And Variable Camshaft Timing (VCT) Unit Bolts
      G03201341Courtesy of FORD MOTOR CO.
  10. Remove the special tool.
    Fig 43: Removing Special Tool
    G03201342Courtesy of FORD MOTOR CO.
  11. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
    Fig 44: Installing Special Tool On Right Cylinder Head
    G03201343Courtesy of FORD MOTOR CO.
  12. Install the special tool on the right cylinder head.
  13. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
    Fig 45: Positioning RH Timing Chain
    G03201344Courtesy of FORD MOTOR CO.
  14. Install the RH timing chain guide.
    Fig 46: Installing RH Timing Chain Guide
    G03201345Courtesy of FORD MOTOR CO.
  15. Install the RH timing chain tensioner arm.
    Fig 47: Installing RH Timing Chain Tensioner Arm
    G03201346Courtesy of FORD MOTOR CO.
  16. Install the RH timing chain tensioner.
    1. Install the timing chain tensioner and bolts.
    2. Remove the drill rod.
    Fig 48: Installing RH Timing Chain Tensioner
    G03201347Courtesy of FORD MOTOR CO.
  17. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.
    CAUTION: Using the special tool, apply 10 N.m (89 lb-in) counterclockwise to the RH exhaust camshaft sprocket.
    Fig 49: Tightening RH Exhaust Camshaft Sprocket And VCT Unit Bolts
    G03201348Courtesy of FORD MOTOR CO.
  18. Tighten the RH exhaust camshaft sprocket and VCT unit bolts in two stages:
    • Stage 1: Tighten to 35 N.m (26 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  19. Remove the special tool.
    Fig 50: Removing Special Tool
    G03201349Courtesy of FORD MOTOR CO.
  20. Remove the special tool.
    Fig 51: Removing Special Tool
    G03201350Courtesy of FORD MOTOR CO.
  21. Install the crankshaft position (CKP) sensor.
    Fig 52: Installing Crankshaft Position (CKP) Sensor
    G03201351Courtesy of FORD MOTOR CO.

Items 52 and 55: Variable Cam Timing (VCT) Bush Carrier Installation Note 

  1. Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting bolts.

Items 58 and 59: Engine Front Cover Installation Note 

    NOTE: If the front cover is not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 53: Identifying Silicone Gasket And Sealant Applying Area
    G03201352Courtesy of FORD MOTOR CO.
  1. Apply silicone gasket and sealant in eight places.
  2. Install the engine front cover.
    • Install new gaskets.
    • Position the engine front cover on the cylinder block.
    • Loosely install the bolts.
    • Tighten the bolts in two stages in the sequence shown.
      • Stage 1: Tighten to 5 N.m (44 lb-in).
      • Stage 2: Tighten to 10 N.m (89 lb-in).
    Fig 54: Identifying Engine Front Cover Bolt Tightening Sequence
    G03201353Courtesy of FORD MOTOR CO.

Items 61-62 and 67-68: Exhaust Manifold Installation Note 

    NOTE: RH is shown, LH is similar.
  1. Install the exhaust manifold.
    • Install a new gasket and the exhaust manifold.
    • Tighten the eight nuts in the sequence shown.
      Fig 55: Identifying Exhaust Manifold Nuts Tightening Sequence
      G03201354Courtesy of FORD MOTOR CO.

Item 67: RH Exhaust Manifold Installation Note 

  1. Install the EGR tube.
    • Install a new EGR tube gasket.
    • Install the EGR tube.
    • Install the EGR tube nuts.
    Fig 56: Installing EGR Tube
    G03201355Courtesy of FORD MOTOR CO.

Items 72-79: RH and LH Valve Cover Installation Note 

    NOTE: RH is shown, LH is similar.
    Fig 57: Installing Gaskets
    G03201356Courtesy of FORD MOTOR CO.
  1. Inspect and install new gaskets as necessary.
  2. NOTE: RH is shown, LH is similar.
    NOTE: If the valve covers are not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 58: Identifying Sealant And Silicone Gasket Applying Area
    G03201357Courtesy of FORD MOTOR CO.
  3. Apply four beads of silicone gasket and sealant as shown. See Fig 58.
  4. NOTE: RH is shown, LH is similar.
  5. Install the valve covers.
    • Tighten the bolts in the sequence shown.
      Fig 59: Identifying Valve Covers Bolt Tightening Sequence
      G03201358Courtesy of FORD MOTOR CO.

Items 81-83: Intake Manifold Installation Note 

  1. Install new intake manifold gaskets.
    Fig 60: Installing New Intake Manifold Gaskets
    G03201359Courtesy of FORD MOTOR CO.
  2. Install the intake manifold and tighten the bolts in the sequence shown.
    Fig 61: Identifying Intake Manifold Bolt Tightening Sequence
    G03201360Courtesy of FORD MOTOR CO.
  3. NOTE: RH is shown, LH is similar.
    Fig 62: Installing Radio Interference Capacitor And Nut
    G03201361Courtesy of FORD MOTOR CO.
  4. Install the radio interference capacitor and the nut.

Item 96: EGR System Module Installation Note 

  1. Connect the EGR system module-to-exhaust manifold tube from the EGR system module.
    Fig 63: Connecting EGR System Module-To-Exhaust Manifold Tube
    G03201362Courtesy of FORD MOTOR CO.

Item 103: Engine Wiring Harness Installation Note 

  1. Install the wiring harness onto the front cover.
    Fig 64: Installing Wiring Harness Onto Front Cover
    G03201363Courtesy of FORD MOTOR CO.
  2. Install the wiring harness onto the front cover.
    Fig 65: Installing Wiring Harness Onto Front Cover
    G03201364Courtesy of FORD MOTOR CO.
  3. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 66: Connecting Crankshaft Position (CKP) Sensor Electrical Connector
    G03201365Courtesy of FORD MOTOR CO.
  4. Install the exhaust gas oxygen sensor (HO2S) connectors onto the brackets.
    Fig 67: Installing Exhaust Gas Oxygen Sensor (HO2S) Connectors Onto Brackets
    G03201366Courtesy of FORD MOTOR CO.
  5. NOTE: LH shown, RH similar.
    Fig 68: Connecting Two Pin-Type Retainers
    G03201367Courtesy of FORD MOTOR CO.
  6. Connect the two pin-type retainers.
  7. NOTE: RH is shown, LH is similar.
    Fig 69: Connecting Variable Cam Timing (VCT) Sensor Electrical Connector
    G03201368Courtesy of FORD MOTOR CO.
  8. Connect the variable cam timing (VCT) sensor electrical connector.
  9. Install the engine wiring harness retainer.
    Fig 70: Installing Engine Wiring Harness Retainer
    G03201369Courtesy of FORD MOTOR CO.
  10. NOTE: LH is shown, RH is similar.
    Fig 71: Connecting Fuel Injector And Radio Interference Capacitor Electrical Connectors
    G03201370Courtesy of FORD MOTOR CO.
  11. Connect the fuel injector and radio interference capacitor electrical connectors.
  12. NOTE: LH shown, RH similar.
    Fig 72: Connecting Ignition Coil Electrical Connectors
    G03201371Courtesy of FORD MOTOR CO.
  13. Connect the ignition coil electrical connectors.
  14. Connect the EGR system module electrical connector.
  15. Connect the generator electrical connector.
    Fig 73: Connecting Generator Electrical Connector
    G03201372Courtesy of FORD MOTOR CO.
  16. NOTE: LH is shown, RH is similar.
    Fig 74: Connecting Engine Wiring Harness Retainers To RH Engine Appearance Cover Support Bracket
    G03201373Courtesy of FORD MOTOR CO.
  17. Connect the engine wiring harness retainers to the RH engine appearance cover support bracket.

Items 106 and 107: Engine Cover Support Bracket Installation Note 

  1. Install the engine wiring harness retainers onto the engine cover support bracket.
    Fig 75: Installing Engine Wiring Harness Retainers Onto Engine Cover Support Bracket
    G03201374Courtesy of FORD MOTOR CO.

Item 109: Oil Level Indicator Tube Installation Note 

    CAUTION: Failure to lubricate the O-ring seal and the oil level indicator tube-to-engine block mating surface with clean engine oil can result in engine oil leaks.
    CAUTION: Make sure the O-ring seal remains in position and does not roll up the indicator tube during installation.
  1. Install a new O-ring seal and the oil level indicator tube.
    • Lubricate the new O-ring seal and engine mating surface with clean engine oil.

Items 122-125: RH and LH Coil Cover Installation Note 

    NOTE: Remove all dirt and moisture from the valve cover before applying silicone sealer.
    Fig 76: Applying Silicone Sealer In Notch Of Valve Cover
    G03201375Courtesy of FORD MOTOR CO.
  1. Lift up the wire harness and apply a 12.7 mm (0.5 in) bead of silicone sealer in the notch of the valve cover.
  2. Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.
    Fig 77: Applying Sealer To Surround Wire Harness And Notch
    G03201376Courtesy of FORD MOTOR CO.
  3. Install the coil cover.
    Fig 78: Installing Coil Cover
    G03201377Courtesy of FORD MOTOR CO.
  4. Connect the wiring harness retainers to the RH valve cover.
    Fig 79: Connecting Wiring Harness Retainers To RH Valve Cover
    G03201378Courtesy of FORD MOTOR CO.
  5. Connect the wiring harness retainers to the RH valve cover.
    Fig 80: Connecting Wiring Harness Retainers To RH Valve Cover
    G03201379Courtesy of FORD MOTOR CO.

Item 129: Front Crankshaft Seal Installation Note 

    NOTE: Lubricate the front oil seal and the engine front cover mating surface with clean engine oil.
    Fig 81: Installing Front Crankshaft Seal Using Special Tool
    G03201380Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the front crankshaft seal.

Items 130-132: Crankshaft Pulley Installation Note 

    NOTE: If the crankshaft pulley is not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 82: Identifying Crankshaft Pulley Keyway
    G03201381Courtesy of FORD MOTOR CO.
  1. Apply silicone gasket and sealant to the crankshaft pulley keyway.
  2. Using the special tool, install the crankshaft pulley.
    Fig 83: Installing Crankshaft Pulley Using Special Tool
    G03201382Courtesy of FORD MOTOR CO.
  3. NOTE: Use strap wrench (303-D055) while tightening crankshaft pulley bolt.
  4. Install the washer and a new bolt and tighten in two stages.
    • Stage 1: Tighten to 80 N.m (59 lb-ft).
    • Stage 2: Tighten an additional 80 degrees.
      Fig 84: Tightening Crankshaft Pulley Bolt Using Strap Wrench (303-D055)
      G03201383Courtesy of FORD MOTOR CO.

Item 134: Coolant Pump Pulley Bolt Installation Note 

  1. Do not tighten coolant pump pulley bolts until after the accessory drive belt has been installed.

Items 144 and 145: Oil Filter and Seal Installation Note 

  1. Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.