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Section 1204 (Engine - 2.3L - (Hybrid)): Assembly: Engine

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0008916Courtesy of FORD MOTOR CO.
 Adapter for 205-126 (205-072-02)
GF0008917Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
GF0000536Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0008918Courtesy of FORD MOTOR CO.
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
GF0008974Courtesy of FORD MOTOR CO.
 Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)
GF0008927Courtesy of FORD MOTOR CO.
 Installer, Front Oil Seal 303-096 (T74P-6150-A)
GF0000267Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0008919Courtesy of FORD MOTOR CO.
 Timing Peg, Crankshaft 303-507
Material

Item Specification
Motorcraft Metal Surface Cleaner
ZC-21		 WSE-M5B392-A
Motorcraft Metal Surface Prep
ZC-31		 -
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only)
VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)		 WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
Silicone Brake Caliper Grease and Dielectric Compound
XG-3-A		 ESE-M1C171-A
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Silicone Gasket Remover
ZC-30		 -
Fig 1: Exploded View Of Lower Engine Block Components (View 1)
GF0042175Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6010 Cylinder block
2 6K318 Crankshaft rear oil seal and retainer
3 6K390 Flywheel
4 7550 Transaxle damper
5 6675 Oil pan
6 6622 Oil pump screen and pickup tube
7 8575 Thermostat assembly
8 6A785 Crankcase vent oil separator
9 6884 Oil filter adapter
10 6A636 Oil filter adapter gasket
Fig 2: Exploded View Of Lower Engine Block Components (View 2)
G00553670Courtesy of FORD MOTOR CO.
Item  Part Number  Description 
1 6161 Piston oil control spacer (4 required)
2 6150 Piston compression upper ring (4 required)
3 6152 Piston compression lower ring (4 required)
4 6159 Piston oil control upper segment ring (4 required)
5 6159 Piston oil control upper segment ring (4 required)
6 6140 Piston pin retainer (8 required)
7 6135 Piston pin (4 required)
8 6200 Connecting rod (4 required)
9 6211 Connecting rod upper bearing (4 required)
10 6110 Piston (4 required)
11 6211 Connecting rod lower bearing (4 required)
12 6210 Connecting rod cap (4 required)
13 6010 Cylinder block
14 6333 Cylinder block crankshaft main bearing (5 required)
15 6303 Crankshaft
16 6333 Crankshaft main bearing beam bearing (5 required)
17 6F098 Main bearing beam
18 6K360 Balance shaft assembly
Fig 3: Front Engine Block Components
GF0042176Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6C301 Accessory drive belt
2 6A228 Accessory drive belt tensioner
3 19D629 A/C compressor
4 8501 Coolant pump
5 6K340 Crankshaft pulley bolt
6 6316 Crankshaft pulley
7 6700 Crankshaft front seal
8 6C315 Crankshaft position (CKP) sensor
9 6019 Engine front cover
10 6K254 Timing chain tensioner
11 6K255 Timing chain tensioner arm
12 6268 Timing chain
13 6K297 Timing chain guide
14 6C271 Oil pump chain tensioner
15 6A895 Oil pump chain
16 6652 Oil pump drive gear
17 6378 Diamond washer
18 6306 Crankshaft sprocket
19 6378 Diamond washer
20 6600 Oil pump
21 6010 Cylinder block
Fig 4: Cylinder Head Components
GF0042177Courtesy of FORD MOTOR CO.
Item Part Number Description
1 12A366 Coil-on-plug assembly
2 6M293 Valve cover
3 12K073 Camshaft position (CMP) sensor
4 6766 Oil filler cap
5 6M293 Valve cover gasket
6 6A284 Camshaft bearing cap
7 6A272 Camshaft (exhaust)
8 6A271 Camshaft (intake)
9 6500 Valve tappet (16 required)
10 6518 Valve collet (16 required)
11 6514 Valve spring retainer (16 required)
12 6513 Valve spring (16 required)
13 6A517 Valve stem seal (16 required)
14 6G004 Cylinder head temperature (CHT) sensor
15 12405 Spark plug (4 required)
16 6065 Cylinder head bolt (10 required)
17 6049 Cylinder head
18 6505 Exhaust valve (8 required)
19 6507 Intake valve (8 required)
20 6051 Head gasket
21 6010 Cylinder block
22 6C251 Camshaft sprocket (2 required)
23 9448 Catalytic converter gasket
24 5E211 Catalytic converter
25 6765 Oil fill extension
Fig 5: Intake Manifold Components
GF0042178Courtesy of FORD MOTOR CO.
Item Part Number Description
1 9288 Fuel supply tube
2 8K556 Coolant outlet
3 9D475 EGR valve
4 9F991 Electronic throttle body
5 6051 Cylinder head gasket
6 6010 Cylinder block
7 12A699 Knock sensor (KS)
8 6754 Oil level indicator and tube assembly
9 9424 Intake manifold
10 9439 Intake manifold gasket
11 8A582 Coolant hose
12 6049 Cylinder head
13 9F593 Fuel injector (4 required)
14 9H487 Fuel rail
NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
    NOTE: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  1. Turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
  2. Remove the engine plug bolt.
    3. Fig 6: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
  3. Install the special tool.
    4. Fig 7: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  4. Install the block-off plate and bolts.
    • Tighten to 25 Nm (18 lb-ft).
    5. Fig 8: Block-Off Plate & Bolts
    GF0024420Courtesy of FORD MOTOR CO.
    NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
  5. Install the oil pump assembly. Tighten the bolts in the sequence shown in the following 2 stages:
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    6. Fig 9: Identifying Tightening Sequence Of Oil Pump Assembly Bolts
    GF0008969Courtesy of FORD MOTOR CO.
  6. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 Nm (89 lb-in).
    7. Fig 10: Locating Oil Pump Pickup Tube Bolts
    GF0024195Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the crankshaft rear main oil seal.
    8. Fig 11: Positioning Crankshaft Rear Oil Seal Using Special Tool (303-328)
    GF0008975Courtesy of FORD MOTOR CO.
  8. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    9. Fig 12: Identifying Tightening Sequence Of Crankshaft Rear Oil Seal Bolts
    GF0008976Courtesy of FORD MOTOR CO.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool and metal surface cleaner to remove traces of sealant.
  9. Clean and inspect all mating surfaces.
    10. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. 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.
  10. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
    • Install the oil pan.
    • Install the 2 oil pan bolts finger-tight.
    11. Fig 13: Identifying Rear Oil Pan Bolts
    G03897723Courtesy of FORD MOTOR CO.
  11. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
    12. Fig 14: Aligning Front Surface Of The Oil Pan
    GF0024104Courtesy of FORD MOTOR CO.
  12. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    13. Fig 15: Identifying Tightening Sequence Of Oil Pan Bolts
    G03897725Courtesy of FORD MOTOR CO.
  13. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    14. Fig 16: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    NOTE: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  14. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  15. Apply silicone gasket and sealant to the locations shown.
    16. Fig 17: Identifying Silicone Gasket And Sealant Location
    G03897827Courtesy of FORD MOTOR CO.
  16. Install a new head gasket.
    17. Fig 18: Identifying Head Gasket
    GF0024202Courtesy of FORD MOTOR CO.
    NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    NOTE: Lubricate the bolts with clean engine oil prior to installation.
  17. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in the following 5 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 15 Nm (11 lb-ft).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
    18. Fig 19: Identifying Tightening Sequence Of Cylinder Head Bolts
    GF0008958Courtesy of FORD MOTOR CO.
    NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  18. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
    • Stage 1: Tighten 1 turn at a time until tight.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (12 lb-ft).
    19. Fig 20: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
    GF0009075Courtesy of FORD MOTOR CO.
    NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
  19. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
    • The crankshaft sprocket flange must be facing away from the engine block.
    20. Fig 21: Locating Washers, Oil Pump Chain & Sprockets
    GF0009076Courtesy of FORD MOTOR CO.
  20. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
    21. Fig 22: Locating Oil Pump Chain, Sprocket & Bolt
    GF0024203Courtesy of FORD MOTOR CO.
  21. Install the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
    22. Fig 23: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
    GF0009078Courtesy of FORD MOTOR CO.
  22. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
    23. Fig 24: Locating Oil Pump Chain Tensioner And Bolt
    GF0024103Courtesy of FORD MOTOR CO.
    NOTE: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  23. Install the special tool in the slots on the rear of both camshafts.
    24. Fig 25: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  24. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    25. Fig 26: Locating Camshaft Sprocket Bolts
    G03897782Courtesy of FORD MOTOR CO.
  25. Install the LH timing chain guide and the bolts.
    • Tighten to 10 Nm (89 lb-in).
    26. Fig 27: Identifying Bolts And LH Timing Chain Guide
    G03897780Courtesy of FORD MOTOR CO.
  26. Install the timing chain.
    27. Fig 28: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  27. Install the RH timing chain guide.
    28. Fig 29: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
    NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
  28. Using the edge of a vise, compress the timing chain tensioner plunger.
    29. Fig 30: Locating Timing Chain Tensioner Plunger
    GF0009079Courtesy of FORD MOTOR CO.
  29. Using a small pick, push back and hold the ratchet mechanism.
    30. Fig 31: Using A Small Pick To Push Back And Hold Ratchet Mechanism
    GF0009080Courtesy of FORD MOTOR CO.
  30. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    31. Fig 32: Pushing Ratchet Arm Back Into Tensioner Housing
    GF0009081Courtesy of FORD MOTOR CO.
  31. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    32. Fig 33: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet Assembly And Plunger
    GF0009082Courtesy of FORD MOTOR CO.
  32. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
    33. Fig 34: Locating Timing Chain Tensioner Bolts And Paper Clip
    GF0024080Courtesy of FORD MOTOR CO.
    NOTE: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  33. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • Tighten to 72 Nm (53 lb-ft).
    34. Fig 35: Locating Camshaft Sprocket Bolts
    GF0024081Courtesy of FORD MOTOR CO.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  34. Clean and inspect the mounting surfaces of the engine and the front cover.
    35. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
  35. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
    36. Fig 36: Locating Silicone Gasket
    G03897744Courtesy of FORD MOTOR CO.
  36. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
    • Tighten the 8-mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
    37. Fig 37: Identifying Engine Front Cover Bolts Tightening Sequence
    GF0024077Courtesy of FORD MOTOR CO.
    NOTE: Remove the through bolt from the special tool.
    NOTE: Lubricate the oil seal with clean engine oil.
  37. Using the special tool, install the crankshaft front oil seal.
    38. Fig 38: Installing Crankshaft Front Oil Seal Using Special Tool
    G03897717Courtesy of FORD MOTOR CO.
    NOTE: Do not install the crankshaft pulley bolt at this time.
    NOTE: Apply clean engine oil on the seal area before installing.
  38. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    39. Fig 39: Locating Crankshaft Pulley & Hole
    GF0008924Courtesy of FORD MOTOR CO.
    NOTE: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
  39. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
    40. Fig 40: Locating Crankshaft Pulley Bolt
    GF0008925Courtesy of FORD MOTOR CO.
  40. Assemble the special tools using 4 hardened washers in the locations shown.
    41. Fig 41: Assembling Special Tools (205-126 And 205-072-02)
    GF0008922Courtesy of FORD MOTOR CO.
    NOTE: The crankshaft must remain in the top dead center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.
    NOTE: Do not reuse the crankshaft pulley bolt.
  41. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
    42. Fig 42: Using Special Tools (205-126 And 205-072-02)
    GF0024073Courtesy of FORD MOTOR CO.
  42. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    43. Fig 43: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  43. Remove the special tool.
    44. Fig 44: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  44. Remove the special tool.
    45. Fig 45: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    NOTE: Only turn the engine in the normal direction of rotation.
  45. Turn the crankshaft clockwise 1 and 3/4 turns.
  46. Install the special tool.
    47. Fig 46: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
    NOTE: Only turn the engine in the normal direction of rotation.
  47. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
    48. Fig 47: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
    NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
  48. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected.
    49. Fig 48: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  49. Install the special tool to check the position of the camshafts.
    • If it is not possible to install the special tool, the engine valve timing must be corrected.
    50. Fig 49: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  50. Remove the special tool.
    51. Fig 50: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
  51. Install a new CKP sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
    52. Fig 51: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
    NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.
  52. Adjust the CKP sensor with the alignment tool.
    • Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
    53. Fig 52: Locating CKP Sensor Bolts
    GF0009614Courtesy of FORD MOTOR CO.
  53. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    54. Fig 53: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  54. Remove the special tool.
    55. Fig 54: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  55. Install the engine plug bolt.
    • Tighten to 20 Nm (15 lb-ft).
    56. Fig 55: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
  56. Clean the valve cover gasket surface with metal surface cleaner.
  57. Apply silicone gasket and sealant to the locations shown.
    58. Fig 56: Applying Silicone Gasket And Sealant
    GF0009086Courtesy of FORD MOTOR CO.
    NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
  58. Install the valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
    59. Fig 57: Identifying Valve Cover Bolts Tightening Sequence
    GF0024067Courtesy of FORD MOTOR CO.
    NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plugs.
  59. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
    • Tighten the CHT sensor to 12 Nm (9 lb-ft).
    • Tighten the spark plugs to 12 Nm (9 lb-ft).
    60. Fig 58: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs
    GF0024191Courtesy of FORD MOTOR CO.
    NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
  60. Install the coil-on-plugs, bolts and the crankcase vent tube.
    • Tighten to 8 Nm (71 lb-in).
    61. Fig 59: Locating Crankcase Vent Tube And Coil-On-Plugs
    GF0024190Courtesy of FORD MOTOR CO.
  61. Install the 3 engine cover studs.
    62. Fig 60: Engine Cover Studs
    GF0024419Courtesy of FORD MOTOR CO.
  62. If equipped, install the block heater.
    • Tighten to 21 Nm (15 lb-ft).
    63. Fig 61: Locating Block Heater
    GF0009034Courtesy of FORD MOTOR CO.
  63. Install the coolant hoses.
    64. Fig 62: Coolant Hoses
    GF0024418Courtesy of FORD MOTOR CO.
    NOTE: Clean the gasket mating surfaces with metal surface cleaner.
  64. Install the oil filter adapter with a new gasket.
    • Tighten to 25 Nm (18 lb-ft).
    65. Fig 63: Oil Filter Adapter & Bolts
    GF0024417Courtesy of FORD MOTOR CO.
    NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
  65. Install the crankcase vent oil separator and the KS.
    • Tighten the oil separator bolts to 10 Nm (89 lb-in).
    • Tighten the KS to 20 Nm (15 lb-ft).
    66. Fig 64: Locating Crankcase Vent Oil Separator, KS And Bolts
    GF0024204Courtesy of FORD MOTOR CO.
  66. Install the coolant hose.
    67. Fig 65: Locating Coolant Bypass Hose
    GF0024185Courtesy of FORD MOTOR CO.
    NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
  67. Install the thermostat housing.
    • Tighten to 10 Nm (89 lb-in).
    68. Fig 66: Thermostat Housing & Bolts
    GF0024416Courtesy of FORD MOTOR CO.
  68. Install the coolant hose.
    69. Fig 67: Coolant Hose
    GF0024415Courtesy of FORD MOTOR CO.
    NOTE: Clean the coolant pump mating surface with metal surface cleaner.
    NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
  69. Install the coolant pump and bolts.
    • Tighten to 10 Nm (89 lb-in).
    70. Fig 68: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
  70. Install the coolant pump pulley and bolts.
    • Tighten to 20 Nm (15 lb-ft).
    71. Fig 69: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  71. Position the engine control wiring harness on the engine and connect the EGR valve electrical connector.
    72. Fig 70: Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    GF0024414Courtesy of FORD MOTOR CO.
  72. Connect the CHT sensor and install the rubber boot.
    73. Fig 71: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
    GF0024184Courtesy of FORD MOTOR CO.
  73. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    74. Fig 72: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-Plug
    GF0024182Courtesy of FORD MOTOR CO.
  74. Install the fuel rail with the fuel injectors and the 2 stud bolts.
    • Tighten to 23 Nm (17 lb-ft).
    75. Fig 73: Identifying Fuel Rail And Stud Bolts
    GF0042061Courtesy of FORD MOTOR CO.
  75. Install the radio capacitor and the nut.
    • Tighten to 10 Nm (89 lb-in).
    76. Fig 74: Identifying Radio Capacitor And Nut
    GF0042060Courtesy of FORD MOTOR CO.
  76. Install the EGR tube.
    • Tighten to 55 Nm (41 lb-ft).
    77. Fig 75: Locating Exhaust Gas Recirculation (EGR) Tube
    GF0024177Courtesy of FORD MOTOR CO.
  77. Position the intake manifold and connect the PCV hose.
    78. Fig 76: Locating Positive Crankcase Ventilation (PCV) Hose
    GF0024176Courtesy of FORD MOTOR CO.
    NOTE: Inspect and install new intake manifold gaskets, if necessary.
  78. Install the intake manifold gasket and intake manifold and 8 bolts.
    • Tighten to 18 Nm (13 lb-ft).
    79. Fig 77: Locating Intake Manifold Gaskets & Intake Manifold
    GF0024175Courtesy of FORD MOTOR CO.
  79. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    80. Fig 78: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
    GF0024173Courtesy of FORD MOTOR CO.
  80. Attach all the wire harness pin-type retainers to the intake manifold.
  81. Connect the 4 fuel injector electrical connectors and the radio capacitor electrical connector.
    82. Fig 79: Identifying Connectors
    GF0042173Courtesy of FORD MOTOR CO.
  82. Attach the pin-type retainer to the intake manifold and connect the KS electrical connector.
    83. Fig 80: Identifying Pin-Type Retainer And Connector
    GF0042172Courtesy of FORD MOTOR CO.
  83. Connect the manifold absolute pressure (MAP) sensor electrical connector.
    84. Fig 81: Identifying (MAP) Connector
    GF0042171Courtesy of FORD MOTOR CO.
  84. Connect the engine oil pressure (EOP) switch electrical connector.
    85. Fig 82: Identifying (EOP) Connector
    GF0042170Courtesy of FORD MOTOR CO.
  85. Connect the evaporative emissions (EVAP) tube quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    86. Fig 83: Identifying EVAP Tube
    GF0042169Courtesy of FORD MOTOR CO.
  86. Connect the lower coolant hose to the throttle body.
    87. Fig 84: Identifying Lower Coolant Hose
    GF0042168Courtesy of FORD MOTOR CO.
  87. Connect the upper coolant hose to the throttle body.
    88. Fig 85: Identifying Upper Coolant Hose
    GF0042167Courtesy of FORD MOTOR CO.
  88. Connect the throttle body electrical connector.
    89. Fig 86: Identifying Connector
    GF0042166Courtesy of FORD MOTOR CO.
  89. Install the oil level indicator tube and the 2 bolts.
    • Tighten the lower bolt to 47 Nm (35 lb-ft).
    • Tighten the upper bolt to 10 Nm (89 lb-in).
    90. Fig 87: Identifying Bolts
    GF0042165Courtesy of FORD MOTOR CO.
  90. Install the accessory drive belt tensioner.
    • Tighten to 25 Nm (18 lb-ft).
    91. Fig 88: Accessory Drive Belt Tensioner & Bolts
    GF0024412Courtesy of FORD MOTOR CO.
  91. Attach the engine wiring harness pin-type retainer.
    92. Fig 89: Engine Wiring Harness Pin-Type Retainer
    GF0024411Courtesy of FORD MOTOR CO.
  92. Install the engine wiring harness connector bracket.
    • Tighten to 15 Nm (11 lb-ft).
    93. Fig 90: Engine Wiring Harness Connector Bracket & Bolt
    GF0024410Courtesy of FORD MOTOR CO.
  93. Connect the CKP sensor electrical connector.
    94. Fig 91: Crankshaft Position (CKP) Sensor Electrical Connector
    GF0024153Courtesy of FORD MOTOR CO.
  94. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
    95. NOTE: Special bolts are used for installation. Do not use standard bolts.
  95. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following 3 stages:
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
    • Stage 3: Tighten to 112 Nm (83 lb-ft).
    96. Fig 92: Identifying Flexplate Bolts Tightening Sequence
    G03897718Courtesy of FORD MOTOR CO.
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