Section 972 (Engine - 4.6L (2V) - F150 Pickup): Assembly: Engine

	Installer, Connecting Rod 303-442 (T93P-6136-A)
	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
	Installer, Crankshaft Front Seal 303-635
	Installer, Front Cover Sea 303-335 (T88T-6701-A)
	Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
	Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH)
	Installer, Crankshaft Rear Slinger 303-517 (T95P-6701-CH)
	Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH)
	Compressor, Valve Spring 303-452 (T91P-6571-AH)
	Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
	Alignment Pins, Cylinder Head 303-1040
	Holding Tool, Crankshaft 303-448 (T93P-6303-A)
	Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent

Engine - Upper End 

Fig 1: Exploded View Of Engine Components - Upper End

Courtesy of FORD MOTOR CO.

Fig 2: Engine Components Description Chart - Upper End

Courtesy of FORD MOTOR CO.

Engine Induction System 

Fig 3: Exploded View Of Engine Induction System Components

Courtesy of FORD MOTOR CO.

Engine - Lower End 

Fig 4: Exploded View Of Engine Components - Lower End

Courtesy of FORD MOTOR CO.

Fig 5: Engine Components Description Chart - Lower End

Courtesy of FORD MOTOR CO.

Engine - Front End 

Fig 6: Exploded View Of Engine Components - Front End

Courtesy of FORD MOTOR CO.

1. Record the main bearing code found on the front of the engine block.
   Fig 7: Identifying Main Bearing Code Found On Front Of Engine Block

   Courtesy of FORD MOTOR CO.
2. Record the main bearing code found on the crankshaft counterweight.
   Fig 8: Identifying Main Bearing Code Found On Crankshaft Counter Weight

   Courtesy of FORD MOTOR CO.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
   • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the number one crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2".
   • Repeat this process for the remaining four main bearings.
   Fig 9: Bearing Select Fit Chart (Standard Bearings)

   Courtesy of FORD MOTOR CO.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
   Fig 10: Bearing Select Fit Chart (Oversized Bearings)

   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.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
NOTE: The upper thrust washers are shown for location purposes only. Do not install the upper thrust washers until the crankshaft is installed, refer to the following 2 steps.
Fig 11: Installing Crankshaft Onto Upper Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
6. Install the crankshaft onto the upper crankshaft main bearings.
NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
Fig 12: Installing Crankshaft Upper Thrust Washer At Back Of No. 5 Upper Main Bearing
Courtesy of FORD MOTOR CO.
7. Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the No. 5 upper main bearing.
NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps.
Fig 13: Installing Rear Main Bearing Cap
Courtesy of FORD MOTOR CO.
8. Install the rear main bearing cap.
9. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block, and keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
10. Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages:
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 14: Identifying Tightening Sequence Of Rear Main Bearing Cap Bolts

    Courtesy of FORD MOTOR CO.
11. Tighten the jack screws against the cylinder block in the sequence shown, in 2 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    Fig 15: Identifying Tightening Sequence Of Jack Screws

    Courtesy of FORD MOTOR CO.
12. Install the side bolts and tighten them in the sequence shown.
    • Tighten to 21 Nm (15 lb-ft).
    Fig 16: Identifying Tightening Sequence Of Side Bolts

    Courtesy of FORD MOTOR CO.
13. Assemble the 8 pistons. For additional information, refer to PISTON .
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.
NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.
Fig 17: Using Special Tools To Install Piston And Connecting Rod With Upper Connecting Rod Bearing In Place
Courtesy of FORD MOTOR CO.
14. Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 18: Removing Connecting Rod Installer
Courtesy of FORD MOTOR CO.
15. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.
NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
16. Position the lower bearing and connecting rod, and install the new bolts loosely.
NOTE: Main bearing caps are removed for clarity.
Fig 19: Identifying Tightening Sequence Of Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
17. Tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 43 Nm (32 lb-ft).
    • Stage 2: Tighten an additional 105 degrees.
18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    Fig 20: Identifying Tightening Sequence Of Oil Pump Bolts

    Courtesy of FORD MOTOR CO.
19. Install the pickup tube spacer.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 21: Installing Pickup Tube Spacer

    Courtesy of FORD MOTOR CO.
CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-ring with clean engine oil.
Fig 22: Positioning Oil Pump Screen And Pickup Tube And Installing Bolts
Courtesy of FORD MOTOR CO.
20. Position the oil pump screen and pickup tube and install the bolts.
    1. Tighten to 25 Nm (18 lb-ft).
    2. Tighten to 10 Nm (89 lb-in).
NOTE: Clean and inspect the mating surfaces, and install a new gasket.
Fig 23: Positioning Oil Filter Adapter And Installing Bolts
Courtesy of FORD MOTOR CO.
21. Position the oil filter adapter and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
Fig 24: Using Special Tools To Position Cylinder Head Gaskets And Cylinder Heads Over Dowels And Installing Cylinder Head Bolts Loosely
Courtesy of FORD MOTOR CO.
22. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
NOTE: RH shown, LH similar.
Fig 25: Identifying Tightening Sequence Of Bolts
Courtesy of FORD MOTOR CO.
23. Tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
24. Install the RH exhaust manifold gasket and the exhaust manifold. Tighten the nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 26: Tightening Exhaust Manifold Nuts In Sequence

    Courtesy of FORD MOTOR CO.
CAUTION: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
Fig 27: Installing RH Engine Support Insulator Bolts
Courtesy of FORD MOTOR CO.
25. Position the RH engine support insulator and install the bolts.
    • Apply Threadlock 262 to the bolt threads prior to installation.
    • Tighten to 63 Nm (46 lb-ft).
CAUTION: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
Fig 28: Installing LH Engine Support Insulator Bolts
Courtesy of FORD MOTOR CO.
26. Position the LH engine support insulator and install the bolts.
    • Apply Threadlock 262 to the bolt threads prior to installation.
    • Tighten to 63 Nm (46 lb-ft).
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
Fig 29: Compressing Tensioner Plunger Using Vise
Courtesy of FORD MOTOR CO.
27. Compress the tensioner plunger, using a vise.
28. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 30: Installing Retaining Clip On Tensioner

    Courtesy of FORD MOTOR CO.
29. Remove the tensioner from the vise.
30. If the copper links are not visible, mark one link on one end and one link on the other end and use as timing marks.
    Fig 31: Marking One Link On One End And One Link On Other End And Use As Timing Marks

    Courtesy of FORD MOTOR CO.
31. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 32: Installing Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
32. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts.
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts.
       • Tighten to 10 Nm (89 lb-in).
       Fig 33: Installing Timing Chain Guides

       Courtesy of FORD MOTOR CO.
33. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
    Fig 34: Identifying Timing Mark

    Courtesy of FORD MOTOR CO.
NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
Fig 35: Positioning Crankshaft so No. 1 Cylinder Is At TDC With Special Tool
Courtesy of FORD MOTOR CO.
34. Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.
35. Remove the Crankshaft Holding Tool.
36. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 36: Aligning Copper (Marked) Link With Timing Mark On LH Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
37. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 37: Aligning Copper (Marked) Link With Timing Mark On LH Camshaft Sprocket

    Courtesy of FORD MOTOR CO.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Fig 38: Positioning LH Timing Chain Tensioner Arm On Dowel Pin And Installing LH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
38. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
39. Remove the retaining clip from the LH timing chain tensioner.
    Fig 39: Removing Retaining Clip From LH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
40. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 40: Aligning Copper (Marked) Link With Timing Mark On RH Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
41. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 41: Aligning Copper (Marked) Link With Timing Marks On RH Camshaft Sprocket

    Courtesy of FORD MOTOR CO.
42. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 42: Installing RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
43. Remove the retaining clip from the RH timing chain tensioner.
    Fig 43: Removing Retaining Clip From RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
44. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    Fig 44: Identifying Camshaft & Crankshaft Alignment Links/Marks

    Courtesy of FORD MOTOR CO.
45. Install the crankshaft sensor ring on the crankshaft.
    Fig 45: Installing Crankshaft Sensor Ring On Crankshaft

    Courtesy of FORD MOTOR CO.
NOTE: Camshaft roller follower is shown removed for clarity.
Fig 46: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
46. Install the special tool between the valve spring coils to prevent valve stem seal damage.
NOTE: The camshaft roller followers must be reinstalled in their original locations.
NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.
NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.
Fig 47: Using Special Tool To Compress Valve Springs And Installing Camshaft Roller Follower
Courtesy of FORD MOTOR CO.
47. Use the special tool to compress the valve springs, and install the camshaft roller follower.
NOTE: The camshaft roller followers must be installed in their original locations.
NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.
48. Repeat the previous 3 steps for each camshaft roller follower.
CAUTION: 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 all traces of old sealant.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
Fig 48: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
Courtesy of FORD MOTOR CO.
49. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
50. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
    Fig 49: Installing New Engine Front Cover Gasket On Engine Front Cover And Positioning Engine Front Cover Onto Dowels

    Courtesy of FORD MOTOR CO.
51. Tighten the engine front cover fasteners in the sequence shown.
    Fig 50: Identifying Tightening Sequence Of Engine Front Cover Fasteners

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Fig 51: Installing Camshaft Position (CMP) Sensor And Bolt
Courtesy of FORD MOTOR CO.
52. Install the camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
Fig 52: Installing Coolant Pump
Courtesy of FORD MOTOR CO.
53. Install the coolant pump.
    1. Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
    2. Position the coolant pump into the engine block.
    3. Install the bolts.
       • Tighten to 25 Nm (18 lb-ft).
54. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 53: Lubricating Engine Front Cover And Crankshaft Front Seal Inner Lip With Clean Engine Oil

    Courtesy of FORD MOTOR CO.
55. Using the special tools, install a new crankshaft front seal into the engine front cover.
    Fig 54: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tools

    Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 55: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
Courtesy of FORD MOTOR CO.
56. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
57. Use the special tool to install the crankshaft pulley.
    Fig 56: Installing Crankshaft Pulley Using Special Tool

    Courtesy of FORD MOTOR CO.
58. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 57: Installing Crankshaft Pulley Bolt & Washer

    Courtesy of FORD MOTOR CO.
59. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 58: Installing Accessory Drive Belt Idler Pulleys, Coolant Pump Pulley And Bolts

    Courtesy of FORD MOTOR CO.
60. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 59: Installing Accessory Drive Belt Tensioner Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
61. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
62. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    Fig 60: Applying Instant Adhesive Completely Around Gasket Groove In LH Valve Cover

    Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 61: Applying Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
Courtesy of FORD MOTOR CO.
63. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
64. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 62: Positioning LH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.
65. Tighten the valve cover bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    Fig 63: Identifying Tightening Sequence For LH Valve Cover Bolts

    Courtesy of FORD MOTOR CO.
66. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    Fig 64: Applying Instant Adhesive Completely Around Gasket Groove In RH Valve Cover

    Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 65: Applying Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
Courtesy of FORD MOTOR CO.
67. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
68. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 66: Positioning RH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.
69. Tighten the valve cover bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    Fig 67: Identifying Tightening Sequence For RH Valve Cover Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil.
Fig 68: Installing Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
70. Install the oil level indicator tube.
    • Install a new O-ring seal on the oil level indicator tube.
    • Install the oil level indicator tube.
    • Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
71. Install the LH exhaust manifold gasket and the exhaust manifold. Tighten the nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 69: Identifying Tightening Sequence Of LH Exhaust Manifold Nuts

    Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 70: Installing Radio Frequency Interference Capacitors And Nuts
Courtesy of FORD MOTOR CO.
72. Install the radio frequency interference capacitors and the nuts.
    • Tighten to 25 Nm (18 lb-ft).
NOTE: Do not reuse the O-ring seal.
NOTE: Lubricate the O-ring seal with clean engine coolant.
Fig 71: Sliding Heater Outlet Tube Forward With New O-Ring Seal Into Cylinder Block
Courtesy of FORD MOTOR CO.
73. Slide the heater outlet tube forward with the new O-ring seal into the cylinder block.
74. Install the heater outlet tube studs.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 72: Installing Heater Outlet Tube Studs

    Courtesy of FORD MOTOR CO.
75. Connect the coolant hoses to the heater outlet tube.
    Fig 73: Connecting Coolant Hoses To Heater Outlet Tube

    Courtesy of FORD MOTOR CO.
76. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
77. Connect the RH radio ignition interference capacitor electrical connector.
    Fig 74: Connecting RH Radio Ignition Interference Capacitor Electrical Connector

    Courtesy of FORD MOTOR CO.
78. Connect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 75: Connecting LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
79. Connect the engine oil pressure (EOP) sensor electrical connector.
    Fig 76: Connecting Engine Oil Pressure (EOP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
80. Connect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
    Fig 77: Connecting Knock Sensor (KS) Electrical Connector And Wiring Harness Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
81. Connect the CMP sensor electrical connectors.
    Fig 78: Connecting CMP Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
82. Connect the CKP sensor electrical connector.
    Fig 79: Connecting CKP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
83. Install the special tool.
    Fig 80: Installing Special Tool

    Courtesy of FORD MOTOR CO.
84. Using a suitable floor crane, remove the engine from the engine stand.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
85. Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 81: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
Courtesy of FORD MOTOR CO.
86. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
87. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
    Fig 82: Installing Crankshaft Rear Seal Retainer Plate And Loosely Install 6 Bolts

    Courtesy of FORD MOTOR CO.
88. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    Fig 83: Identifying Tightening Sequence Of Rear Seal Retainer Plate

    Courtesy of FORD MOTOR CO.
CAUTION: 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 all traces of old sealant.
89. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 84: Applying Silicone Gasket And Sealant At Crankshaft Rear Seal Retainer Plate-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
90. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 85: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
91. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
92. Install the oil pan gasket and the oil pan and loosely install the bolts.
    Fig 86: Installing Oil Pan Gasket And Oil Pan And Loosely Installing Bolts

    Courtesy of FORD MOTOR CO.
93. Tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    • Stage 3: Tighten an additional 60 degrees.
    Fig 87: Identifying Bolt Tightening Sequence

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Fig 88: Installing Crankshaft Rear Oil Seal Using Special Tools
Courtesy of FORD MOTOR CO.
94. Using the special tools, install a new crankshaft rear seal.
95. Using the special tools, install a new crankshaft rear oil slinger.
    Fig 89: Installing Crankshaft Rear Oil Slinger Using Special Tools

    Courtesy of FORD MOTOR CO.
96. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
    Fig 90: Identifying Tightening Sequence Of Flexplate Bolts

    Courtesy of FORD MOTOR CO.