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Section 463 (Engine - 4.0L SOHC): Assembly: Engine

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools (1 Of 2)
G03274828Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tools (2 Of 2)
G03274829Courtesy of FORD MOTOR CO.
MATERIAL SPECIFICATION

Item Specification
Super Premium SAE 5W-30 Motor Oil
XO-5W30-QSP or equivalent		 WSS-M2C205-A
Metal Surface Cleaner
F4AZ-19536-RA or equivalent		 WSE-M5B392-A
Silicone Gasket and Sealant
F7AZ-19554-EA or equivalent		 WSE-M4G323-A4
Silicone Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A or equivalent		 ESA-M1C171-A

ALL VEHICLES 

CAUTION: If the fuel supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
NOTE: Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.
    NOTE: Lubricate the crankshaft main bearings with clean engine oil before installation.
  1. Install the crankshaft upper main bearings and the thrust bearing.
    2. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    Fig 3: Installing Crankshaft
    G03274830Courtesy of FORD MOTOR CO.
  2. Install the crankshaft.
    3. NOTE: The rear main bearing cap must be installed within four minutes after applying the silicone.
    Fig 4: Applying Sealant To Rear Main Bearing Cap To Cylinder Block Parting Line
    G03274831Courtesy of FORD MOTOR CO.
  3. Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
    4. NOTE: Lubricate the crankshaft main bearings with clean engine oil before installation.
  4. Install the crankshaft lower main bearings in the main bearing caps.
  5. Install the main bearing caps.
    Fig 5: Installing Main Bearing Caps
    G03274832Courtesy of FORD MOTOR CO.
  6. Tighten the main bearing cap bolts in two stages in the sequence shown.
    1. Tighten bolts to 35 N.m (26 lb-ft).
    2. Tighten bolts an additional 57 degrees.
      Fig 6: Main Bearing Cap Bolts Tightening Sequence
      G03274833Courtesy of FORD MOTOR CO.
  7. Lubricate the piston rings with clean engine oil.
  8. Make sure that the piston rings are correctly spaced. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
    Fig 7: Installing Rubber Hose Pieces On Connecting Rod Bolts To Protect Crankshaft
    G03274834Courtesy of FORD MOTOR CO.
    10. NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.
    NOTE: Lubricate the cylinder wall with clean engine oil.
    Fig 8: Installing Pistons
    G03274835Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the pistons.
    11. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.
  11. Check the clearance of each connecting rod bearing. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  12. Rotate the crankshaft until the piston is at the bottom of its stroke.
    13. NOTE: For cylinders 1, 2, and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5, and 6, remove the opposite nut first.
    Fig 9: Loosening First Nut
    G03274836Courtesy of FORD MOTOR CO.
  13. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
  14. Tap the bolt on the nut until it can be removed by hand.
    Fig 10: Taping On Bolt
    G03274837Courtesy of FORD MOTOR CO.
  15. Repeat previous two steps for the opposite bolt.
  16. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.
    Fig 11: Installing New Bolts
    G03274838Courtesy of FORD MOTOR CO.
  17. Install the connecting rod cap in the original position.
  18. Install and tighten the connecting rod nuts finger tight.
    Fig 12: Installing And Tighten Connecting Rod Nuts Finger Tight
    G03274839Courtesy of FORD MOTOR CO.
  19. Tighten the connecting rod nuts in two stages in pairs.
    • Stage 1: Tighten nuts to 20 N.m (15 lb-ft).
    • Stage 2: Tighten nuts an additional 90 degrees.
  20. Repeat previous four steps for the remaining connecting rods.
  21. Rotate the crankshaft until No.1 piston is at top dead center (TDC).
  22. Install the oil pump and the bolts.
    Fig 13: Installing Oil Pump And Bolts
    G03274840Courtesy of FORD MOTOR CO.
  23. Install the jackshaft.
    Fig 14: Installing Jackshaft
    G03274841Courtesy of FORD MOTOR CO.
  24. Install the jackshaft thrust plate and the bolts.
    Fig 15: Installing Jackshaft Thrust Plate And Bolts
    G03274842Courtesy of FORD MOTOR CO.
  25. Install the jackshaft spacer.
    Fig 16: Installing Jackshaft Spacer
    G03274843Courtesy of FORD MOTOR CO.
  26. Install the oil pump drive and the hold down.
    Fig 17: Installing Oil Pump Drive And Hold Down
    G03274844Courtesy of FORD MOTOR CO.
  27. Position the RH camshaft drive cassette and install the sprocket bolt. Do not tighten the bolt at this time.
    Fig 18: Positioning RH Camshaft Drive Cassette And Install Sprocket Bolt
    G03274845Courtesy of FORD MOTOR CO.
  28. Install the RH camshaft drive cassette bolt and spacer.
    Fig 19: Installing RH Camshaft Drive Cassette Bolt And Spacer
    G03274846Courtesy of FORD MOTOR CO.
  29. Install the front cassette and bolt.
    Fig 20: Installing Front Cassette And Bolt
    G03274847Courtesy of FORD MOTOR CO.
  30. Position the jackshaft sprocket and chain.
    Fig 21: Positioning Jackshaft Sprocket And Chain
    G03274848Courtesy of FORD MOTOR CO.
  31. Install the chain guide and bolts.
    Fig 22: Installing Chain Guide And Bolts
    G03274849Courtesy of FORD MOTOR CO.
  32. Install the chain tensioner and the bolts.
    Fig 23: Installing Chain Tensioner And Bolts
    G03274850Courtesy of FORD MOTOR CO.
  33. Install the bolt. Do not tighten at this time.
    Fig 24: Installing Bolt
    G03274851Courtesy of FORD MOTOR CO.
  34. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt to 20 N.m (15 lb-ft).
    Fig 25: Tightening Rear Bolt
    G03274852Courtesy of FORD MOTOR CO.
  35. Install the special tool on the rear of the jackshaft.
  36. Tighten the rear bolt an additional 90 degrees.
    Fig 26: Tightening Rear Bolt An Additional 90 Degrees
    G03274853Courtesy of FORD MOTOR CO.
  37. Tighten the front bolt in two stages.
    • Stage 1: Tighten to 45 N.m (33 lb-ft).
    • Stage 2: Tighten 90 degrees.
      Fig 27: Tightening Front Bolt
      G03274854Courtesy of FORD MOTOR CO.
  38. Install the rear jackshaft plug.
    Fig 28: Installing Rear Jackshaft Plug
    G03274855Courtesy of FORD MOTOR CO.
  39. Position the front cover gasket and install the front cover.
    Fig 29: Positioning Front Cover Gasket And Install Front Cover
    G03274856Courtesy of FORD MOTOR CO.
    40. CAUTION: Failure to back off the set screws can result in damage to the cylinder block cradle.
    NOTE: The set screw is shown from the top (crankshaft) side of the cylinder block cradle.
    Fig 30: Backing Off Eight Set Screws
    G03274857Courtesy of FORD MOTOR CO.
  40. Back the eight set screws (7/16-inch Hex) off until they are below the cylinder block cradle boss.
    41. NOTE: If the cylinder block cradle gasket is not secured within four minutes of the sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow the metal surface cleaner 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 31: Applying Silicone In Six Places
    G03274858Courtesy of FORD MOTOR CO.
  41. Apply silicone in the six places shown.
  42. Position the cylinder block cradle and gasket assembly.
    Fig 32: Positioning Cylinder Block Cradle And Gasket Assembly
    G03274859Courtesy of FORD MOTOR CO.
  43. Install and hand-tighten the fifteen bolts and two nuts.
    Fig 33: Installing Fifteen Bolts And Two Nuts
    G03274860Courtesy of FORD MOTOR CO.
  44. Install and hand-tighten the rear cylinder block cradle bolts.
    Fig 34: Installing Rear Cylinder Block Cradle Bolts
    G03274861Courtesy of FORD MOTOR CO.
    45. NOTE: The cylinder block cradle to cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) ladder frame undervalues or mm (0.00196 in) cylinder block cradle protrusion.
    Fig 35: Aligning Transmission Face Of Cylinder Block Cradle With Rear Face Of Cylinder Block
    G03274862Courtesy of FORD MOTOR CO.
  45. Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.
  46. Tighten the fifteen bolts and two nuts.
    Fig 36: Tightening Fifteen Bolts And Two Nuts
    G03274863Courtesy of FORD MOTOR CO.
  47. Tighten the rear cylinder block cradle bolts.
    Fig 37: Tightening Rear Cylinder Block Cradle Bolts
    G03274864Courtesy of FORD MOTOR CO.
  48. Tighten the eight set screws (7/16-inch Hex).
    Fig 38: Tightening Eight Set Screws
    G03274865Courtesy of FORD MOTOR CO.
  49. Install new seals on the two silver bolts and position them in the cylinder block cradle.
    Fig 39: Installing New Seals On Two Silver Bolts
    G03274866Courtesy of FORD MOTOR CO.
  50. Position the six remaining bolts.
    Fig 40: Positioning Six Remaining Bolts
    G03274867Courtesy of FORD MOTOR CO.
  51. Tighten the cylinder block cradle inner bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 15 N.m (11 lb-ft).
    • Stage 2: Tighten to 33 N.m (24 lb-ft).
      Fig 41: Tightening Cylinder Block Cradle Inner Bolts
      G03274868Courtesy of FORD MOTOR CO.
    52. NOTE: Assemblies that measure out of specification must have the entire assembly procedure repeated.
    Fig 42: Measuring Step Between Rear Face Of Cylinder Block And Transmission Face Of Cylinder Block Cradle
    G03274869Courtesy of FORD MOTOR CO.
  52. Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.
  53. Repair all assemblies that exceed undervalues specification by installing shims on one or both sides of the cylinder block cradle.
    Fig 43: Repairing All Assemblies That Exceed Undervalues Specification
    G03274870Courtesy of FORD MOTOR CO.
  54. Install the oil pump screen cover and tube.
    Fig 44: Installing Oil Pump Screen Cover And Tube
    G03274871Courtesy of FORD MOTOR CO.
  55. Install the gasket, and the oil pan.
    Fig 45: Installing Gasket, And Oil Pan
    G03274872Courtesy of FORD MOTOR CO.
  56. Install the oil filter adapter.
    Fig 46: Installing Oil Filter Adapter
    G03274873Courtesy of FORD MOTOR CO.
  57. Install the oil filter.
    Fig 47: Installing Oil Filter
    G03274874Courtesy of FORD MOTOR CO.
  58. Install the coolant pump.
    Fig 48: Installing Coolant Pump
    G03274875Courtesy of FORD MOTOR CO.
    59. NOTE: LH shown, RH similar.
    Fig 49: Installing Cylinder Head Gaskets
    G03274876Courtesy of FORD MOTOR CO.
  59. Install the cylinder head gaskets.
    60. NOTE: LH shown, RH similar.
    NOTE: Cylinder head bolts are a torque-to-yield design. New bolts must be installed.
  60. Install the 12 mm (0.47 in) bolts and tighten in the sequence shown in two stages.
    • Stage 1: Tighten to 12 Nm (9 lb-ft).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
      Fig 50: Cylinder Head Bolts Tightening Sequence
      G03974329Courtesy of FORD MOTOR CO.
    61. NOTE: LH shown, RH similar.
    Fig 51: Installing Two 8 mm Bolts
    G03974330Courtesy of FORD MOTOR CO.
  61. Install the two 8 mm (0.31 in) bolts.
    62. NOTE: LH Shown, RH similar.
  62. Tighten the 12 mm (0.47 in) bolts in two stages in the sequence shown.
    • Stage 1: Tighten bolts 90 degrees.
    • Stage 2: Tighten bolts an additional 90 degrees.
      Fig 52: Cylinder Head Bolts Tightening Sequence - Torque Angle
      G03974331Courtesy of FORD MOTOR CO.
    63. NOTE: Late build pulley shown, early build pulley similar.
    Fig 53: Installing Crankshaft Pulley
    G03274880Courtesy of FORD MOTOR CO.
  63. Using the special tool, install the crankshaft pulley.
    64. CAUTION: A new bolt must be used each time it is removed.
    NOTE: Late build pulley shown, early build pulley similar.
  64. Tighten the crankshaft pulley bolt in two stages.
    • Stage 1: Tighten to 50 N.m (37 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 54: Tightening Crankshaft Pulley Bolt
      G03274881Courtesy of FORD MOTOR CO.
  65. Position the RH camshaft sprocket in the chain and install it on the camshaft.
    Fig 55: Positioning RH Camshaft Sprocket In Chain
    G03274882Courtesy of FORD MOTOR CO.
    66. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
    Fig 56: Installing RH Camshaft Sprocket Bolt
    G03274883Courtesy of FORD MOTOR CO.
  66. Install the RH camshaft sprocket bolt.
  67. Install the RH chain guide bolt.
    Fig 57: Installing RH Chain Guide Bolt
    G03274884Courtesy of FORD MOTOR CO.
  68. Position the LH camshaft sprocket in the chain and install it on the camshaft.
    Fig 58: Positioning LH Camshaft Sprocket In Chain & On Camshaft
    G03274885Courtesy of FORD MOTOR CO.
    69. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
    Fig 59: Installing LH Camshaft Sprocket Bolt
    G03274886Courtesy of FORD MOTOR CO.
  69. Install the LH camshaft sprocket bolt.
  70. Install the chain guide bolt.
    Fig 60: Installing Chain Guide Bolt
    G03274887Courtesy of FORD MOTOR CO.
  71. Turn the crankshaft one revolution clockwise.
    72. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.
    NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).
    Fig 61: Installing Special Tool
    G03274888Courtesy of FORD MOTOR CO.
  72. Install the special tool.
    73. NOTE: Camshaft timing slots are off-center.
    Fig 62: Installing Special Tools On Front Of RH Cylinder Head
    G03274889Courtesy of FORD MOTOR CO.
  73. Position the camshaft timing slots below centerline of camshaft and install the special tools on the front of the RH cylinder head.
    74. NOTE: Leave the top two special tool clamp bolts loose.
    Fig 63: Installing Special Tools On Rear Of RH Cylinder Head
    G03274890Courtesy of FORD MOTOR CO.
  74. Install the special tools on the rear of the RH cylinder head.
  75. Install the special tool.
    Fig 64: Installing Special Tool
    G03274891Courtesy of FORD MOTOR CO.
    76. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
  76. Tighten the bolts.
    1. Tighten the special tool top two clamp bolts to 10 N.m (89 lb-in).
    2. Tighten the camshaft bolt.
      Fig 65: Tightening Camshaft Bolt
      G03274892Courtesy of FORD MOTOR CO.
  77. Install the RH camshaft tensioner.
    Fig 66: Installing RH Camshaft Tensioner
    G03274893Courtesy of FORD MOTOR CO.
    78. NOTE: Do not tighten the special tool top two clamp bolts. Camshaft sprocket must rotate freely.
    Fig 67: Installing Special Tools On Front Of LH Cylinder Head
    G03274894Courtesy of FORD MOTOR CO.
  78. Install the special tools on the front of the LH cylinder head.
    79. NOTE: Camshaft timing slots are off-center.
    Fig 68: Installing Special Tools On Rear Of LH Cylinder Head
    G03274895Courtesy of FORD MOTOR CO.
  79. Position the camshaft timing slots below centerline of camshaft and install the special tools on the rear of the LH cylinder head.
  80. Install the special tool.
    Fig 69: Installing Special Tool
    G03274896Courtesy of FORD MOTOR CO.
  81. Tighten the bolts.
    1. Tighten the special tool top two clamp bolts to 10 N.m (89 lb-in).
    2. Tighten the camshaft bolt.
      Fig 70: Tightening Camshaft Bolt
      G03274897Courtesy of FORD MOTOR CO.
  82. Install the LH camshaft tensioner.
    Fig 71: Installing LH Camshaft Tensioner
    G03274898Courtesy of FORD MOTOR CO.
    83. NOTE: Lubricate the parts with clean engine oil prior to installing.
    Fig 72: Installing Roller Followers In Their Original Position
    G03274899Courtesy of FORD MOTOR CO.
  83. Using the special tool, install the roller followers in their original position.
  84. Install the gasket and the LH exhaust manifold and nuts.
    Fig 73: Installing Gasket And LH Exhaust Manifold
    G03274900Courtesy of FORD MOTOR CO.
  85. Install the gasket and the RH exhaust manifold and nuts.
    Fig 74: Installing Gasket And RH Exhaust Manifold
    G03274901Courtesy of FORD MOTOR CO.
    86. NOTE: Prior to installation, use metal surface cleaner to clean mating surfaces.
    Fig 75: Installing Knock Sensor
    G03274902Courtesy of FORD MOTOR CO.
  86. Install the knock sensor (KS) and the bolt.
  87. Install the oil level indicator tube and the bolt.
    Fig 76: Installing Oil Level Indicator Tube
    G03274903Courtesy of FORD MOTOR CO.
  88. Install the thermostat housing.
    1. Install the housing into the bypass hose.
    2. Install the bolts.
    3. Position the bypass hose clamp.
      Fig 77: Installing Thermostat Housing
      G03274904Courtesy of FORD MOTOR CO.
  89. Install the gasket and the RH valve cover.
    Fig 78: Installing Gasket And RH Valve Cover
    G03274905Courtesy of FORD MOTOR CO.
  90. Install the gasket and the LH valve cover.
    Fig 79: Installing Gasket And LH Valve Cover
    G03274906Courtesy of FORD MOTOR CO.
  91. Install the positive crankcase ventilation (PCV) valve and hoses.
    Fig 80: Installing PCV Valve And Hoses
    G03274907Courtesy of FORD MOTOR CO.

    92. EARLY BUILD VEHICLES 

  92. Connect the PCV hose to the valve.
    Fig 81: Connecting PCV Hose To Valve
    G03274908Courtesy of FORD MOTOR CO.

    93. LATE BUILD VEHICLES 

  93. Connect the PCV hose to the valve.
    Fig 82: Connecting PCV Hose To Valve
    G03274909Courtesy of FORD MOTOR CO.

    94. ALL VEHICLES 

  94. Install the fuel injection supply manifold.
    1. Install the fuel injection supply manifold and the fuel injectors as an assembly.
    2. Install the fuel supply tube to the fuel manifold.
      Fig 83: Installing Fuel Supply Tube To Fuel Manifold
      G03274910Courtesy of FORD MOTOR CO.
  95. Install the fuel supply tube lower bracket and bolt.
    Fig 84: Installing Fuel Supply Tube Lower Bracket
    G03274911Courtesy of FORD MOTOR CO.
  96. Install the fuel supply tube upper bracket and bolt.
    Fig 85: Installing Fuel Supply Tube Upper Bracket
    G03274912Courtesy of FORD MOTOR CO.
  97. Install and connect the exhaust gas recirculation (EGR) valve tube to the exhaust manifold.
    Fig 86: Installing And Connect EGR Valve Tube To Exhaust Manifold
    G03274913Courtesy of FORD MOTOR CO.
  98. Install the fuel charging wiring.
    Fig 87: Installing Fuel Charging Wiring
    G03274914Courtesy of FORD MOTOR CO.
    99. NOTE: LH shown, RH similar.
    Fig 88: Connecting Six Fuel Injector Electrical Connectors
    G03274915Courtesy of FORD MOTOR CO.
  99. Connect the six fuel injector electrical connectors.
  100. Connect the fuel pulse damper vacuum hose.
    Fig 89: Connecting Fuel Pulse Damper Vacuum Hose
    G03274916Courtesy of FORD MOTOR CO.
  101. Connect the coolant temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
    Fig 90: Connecting Coolant Temperature Indicator Sender Unit
    G03274917Courtesy of FORD MOTOR CO.
  102. Connect the wiring harness retainers.
    Fig 91: Connecting Wiring Harness Retainers
    G03274918Courtesy of FORD MOTOR CO.
  103. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 92: Connecting CKP Sensor Electrical Connector
    G03274919Courtesy of FORD MOTOR CO.
  104. Install the coolant tube bracket and bolts.
    Fig 93: Installing Coolant Tube Bracket
    G03274920Courtesy of FORD MOTOR CO.
  105. Attach the wiring harness retainer and install the heater tube bracket assembly.
    Fig 94: Attaching Wiring Harness Retainer And Install Heater Tube Bracket Assembly
    G03274921Courtesy of FORD MOTOR CO.
  106. Connect the heater hose and the PCV coolant hose.
    Fig 95: Connecting Heater Hose And PCV Coolant Hose
    G03274922Courtesy of FORD MOTOR CO.
  107. Install the coolant hose.
    Fig 96: Installing Coolant Hose
    G03274923Courtesy of FORD MOTOR CO.
  108. Position the intake manifold close to the installed position.
  109. Install the heated PCV fitting and the bolts.
    Fig 97: Installing Heated PCV Fitting
    G03274924Courtesy of FORD MOTOR CO.
  110. Install the intake manifold and the bolts.
    Fig 98: Installing Intake Manifold
    G03274925Courtesy of FORD MOTOR CO.
  111. Connect and attach the electrical connector.
    Fig 99: Connecting And Attach Electrical Connector
    G03274926Courtesy of FORD MOTOR CO.
  112. Connect the vacuum hoses.
    Fig 100: Connecting Vacuum Hoses
    G03274927Courtesy of FORD MOTOR CO.
  113. Position the ignition coil and bracket assembly and install the upper bracket bolts.
    Fig 101: Positioning Ignition Coil And Bracket Assembly
    G03274928Courtesy of FORD MOTOR CO.
  114. Install the ignition coil bracket lower bolts.
    Fig 102: Installing Ignition Coil Bracket Lower Bolts
    G03274929Courtesy of FORD MOTOR CO.
  115. Connect the ignition coil electrical connector.
    Fig 103: Connecting Ignition Coil Electrical Connector
    G03274930Courtesy of FORD MOTOR CO.
    116. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.
    NOTE: Apply dielectric compound to the inside of the spark plug boots.
  116. Connect the spark plug wires to the spark plugs.
  117. Install the bolt and connect the radio ignition interference capacitor electrical connector.
    Fig 104: Connecting Radio Ignition Interference Capacitor Electrical Connector
    G03274931Courtesy of FORD MOTOR CO.
  118. Connect the camshaft position (CMP) sensor and the differential pressure feedback EGR system electrical connectors. Attach the wiring pin-type retainer.
    Fig 105: Connecting CMP Sensor And Differential Pressure Feedback EGR System Connectors
    G03274932Courtesy of FORD MOTOR CO.
  119. Connect the EGR vacuum regulator solenoid valve electrical and vacuum connections.
    Fig 106: Connecting EGR Vacuum Regulator Solenoid Valve Electrical And Vacuum Connections
    G03274933Courtesy of FORD MOTOR CO.
  120. Connect the following:
    • EGR valve vacuum hose.
    • EGR tube to the valve.
      Fig 107: Connecting EGR Tube To Valve And Vacuum Hose
      G03274934Courtesy of FORD MOTOR CO.
  121. Connect the idle air control (IAC) and the throttle position (TP) sensor electrical connector. Attach the TP sensor wiring routing clips.
    Fig 108: Connecting IAC & TP Sensor Connectors
    G03274935Courtesy of FORD MOTOR CO.
  122. Install the generator mounting bracket.
    1. Install the generator mounting bracket and bolts.
    2. Install the drive belt tensioner bolt.
      Fig 109: Installing Generator Mounting Bracket
      G03274936Courtesy of FORD MOTOR CO.
    123. NOTE: The lifting eyes should be installed on the exhaust manifold studs for number three and number four cylinders.
  123. Install the Lifting Eyes.
  124. Install the Spreader Bar to the Lifting Eyes.
  125. Attach a floor crane to the Spreader Bar and remove the engine from the engine stand.
    126. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface cleaner.
    Fig 110: Installing Crankshaft Rear Oil Seal On Special Tool
    G03274937Courtesy of FORD MOTOR CO.
  126. Lubricate the crankshaft rear oil seal with clean engine oil and install on the special tool.
  127. Using the special tool, install the crankshaft rear oil seal.
    Fig 111: Installing Crankshaft Rear Oil Seal
    G03274938Courtesy of FORD MOTOR CO.
    128. NOTE: Special bolts are used for flywheel installation. Do not use standard bolts.
  128. Install the flywheel. Tighten the bolts in two stages in the sequence shown.
    1. Tighten the bolts to 13 N.m (10 lb-ft).
    2. Tighten the bolts to 71 N.m (52 lb-ft).
      Fig 112: Flywheel Bolts Tightening Sequence
      G03274939Courtesy of FORD MOTOR CO.
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