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Intake Manifold

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Fig 1: Exploded View Of Intake Manifold
G06390173Courtesy of FORD MOTOR CO.
PART NUMBER REFERENCE

Item Part Number Description
1 9288 Fuel supply tube
2 8K556 Coolant outlet
3 9D475 EGR valve
4 9F991 Electronic Throttle Body (TB)
5 6051 Cylinder head gasket
6 6010 Cylinder block
7 12A699 Knock Sensor (KS)
8 9424 Intake manifold
9 9439 Intake manifold gasket (4 required)
10 8A582 Coolant hose
11 6049 Cylinder head
12 9F593 Fuel injector (4 required)
13 9H487 Fuel rail
14 - Fuel rail insulator
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 the pulley bolt is loosened. 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. All parts must be thoroughly cleaned and 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: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to GENERAL PROCEDURES .
    NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.
    NOTE: The front bulkhead does not have an oil squirter.
  1. Install the 4 oil squirters.
    • Tighten to 4 Nm (35 lb-in).
      Fig 2: Locating Oil Squirters
      G06390174Courtesy of FORD MOTOR CO.
  2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
    Fig 3: Measuring Each Of Crankshaft Main Bearing Journal Diameters
    G06390175Courtesy of FORD MOTOR CO.
  3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    Fig 4: Locating Main Bearing Beam
    G06390176Courtesy of FORD MOTOR CO.
  4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
      Fig 5: Identifying Main Bearing Beam Bolts Tightening Sequence
      G06390177Courtesy of FORD MOTOR CO.
  5. Measure each crankshaft block main bearing bore diameter.
    • Remove the bolts and the main bearing beam.
    • Discard the main bearing beam bolts.
      Fig 6: Identifying Crankshaft Block Main Bearing Bore Diameter
      G06390178Courtesy of FORD MOTOR CO.
  6. Using the chart, select the crankshaft main bearings.
    Fig 7: Crankshaft Main Bearings Chart
    G06390179Courtesy of FORD MOTOR CO.
    7. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
  7. Using the original connecting rod cap bolts, install the connecting caps and bolts.
    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
    • Remove the bolts and the connecting rod cap.
    • Discard the connecting rod cap bolts.
      Fig 8: Measuring Connecting Rod Large End Bore
      G06390180Courtesy of FORD MOTOR CO.
  9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
    Fig 9: Measuring Each Of Crankshaft Connecting Rod Bearing Journal Diameters
    G06390181Courtesy of FORD MOTOR CO.
  10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    Fig 10: Connecting Rod Bearings Chart
    G06390182Courtesy of FORD MOTOR CO.
    11. 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.
    NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
    NOTE: The center bulkhead is the thrust bearing.
    Fig 11: Locating Main Bearings
    G06390183Courtesy of FORD MOTOR CO.
  11. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
    12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
    Fig 12: Locating Main Bearings
    G06390184Courtesy of FORD MOTOR CO.
  12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
  13. Lubricate journals on the crankshaft with clean engine oil.
  14. Position the crankshaft in the cylinder block.
    Fig 13: Locating Crankshaft Gear
    G06390185Courtesy of FORD MOTOR CO.
  15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
    Fig 14: Locating Main Bearing Beam Side Fit Surfaces
    G06390186Courtesy of FORD MOTOR CO.
  16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    Fig 15: Locating Main Bearing Beam
    G06390187Courtesy of FORD MOTOR CO.
    17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
    NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.
  17. Install and tighten the 10 new main bearing beam bolts.
    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
      Fig 16: Identifying Main Bearing Beam Bolts Tightening Sequence
      G06390188Courtesy of FORD MOTOR CO.
  18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
    • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge with Holding Fixture.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
      Fig 17: Measuring Crankshaft End Play
      G06390189Courtesy of FORD MOTOR CO.
    19. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
    NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
    NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
  19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
    • When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
    • The position of the upper and lower compression ring gaps are not controlled for installation.
      Fig 18: Identifying Piston Ring Compressor And Connecting Rod Installer
      G06390190Courtesy of FORD MOTOR CO.
    20. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
    NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
  20. Install the connecting rod caps and the new bolts.
    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 19: Identifying Connecting Rod Cap Bolts Tightening Sequence
      G06390191Courtesy of FORD MOTOR CO.
  21. Install the Crankshaft TDC  Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg. The engine is now at Top Dead Center (TDC).
    Fig 20: Installing Crankshaft TDC Timing Peg
    G06390192Courtesy of FORD MOTOR CO.
    22. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
    NOTE: The original adjustment shims must be installed in their original position.
    NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.
  22. Install the adjustment shims in their original position on the seat faces of the balancer unit.
  23. With the balancer unit shaft marks in the TDC  position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
    Fig 21: Locating Balancer Unit And Shafts Reference Mark
    G06390193Courtesy of FORD MOTOR CO.
  24. Install the balancer unit bolts.
    • Tighten in the sequence shown in 2 stages.
      • Stage 1: Tighten to 25 Nm (18 lb-ft).
      • Stage 2: Tighten to 50 Nm (37 lb-ft).
        Fig 22: Identifying Balancer Unit Bolts Tightening Sequence
        G06390194Courtesy of FORD MOTOR CO.
  25. Remove the Crankshaft TDC  Timing Peg.
    Fig 23: Installing Crankshaft TDC Timing Peg
    G06390195Courtesy of FORD MOTOR CO.
  26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
  27. Install the Crankshaft TDC  Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg.
    • Remove the Crankshaft TDC  Timing Peg.
      Fig 24: Installing Crankshaft TDC Timing Peg
      G06390196Courtesy of FORD MOTOR CO.
    28. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown.
  28. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
    • Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
    • Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
    • If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. For additional information, refer to BALANCE SHAFT BACKLASH .
      Fig 25: Measuring Gear Backlash
      G06390197Courtesy of FORD MOTOR CO.
    29. 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.
  29. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
    30. NOTE: The Crankshaft TDC  Timing Peg 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.
    Fig 26: Installing Crankshaft TDC Timing Peg
    G06390198Courtesy of FORD MOTOR CO.
  30. Install the Crankshaft TDC  Timing Peg.
  31. Install the block-off plate and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 27: Locating Block-Off Plate Bolts
      G06390199Courtesy of FORD MOTOR CO.
    32. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.
  32. 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 (177 lb-in).
      Fig 28: Identifying Oil Pump Assembly Bolts Tightening Sequence
      G06390200Courtesy of FORD MOTOR CO.
  33. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 Nm (89 lb-in).
      Fig 29: Locating Bolts, Oil Pump Pickup Tube And Gasket
      G06390201Courtesy of FORD MOTOR CO.
  34. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.
    Fig 30: Identifying Crankshaft Rear Main Oil Seal Installer
    G06390202Courtesy of FORD MOTOR CO.
  35. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
      Fig 31: Identifying Crankshaft Rear Oil Seal Retainer Plate Bolts Tightening Sequence
      G06390203Courtesy of FORD MOTOR CO.
    36. 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.
  36. Clean and inspect all mating surfaces.
    37. 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 prep. 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.
  37. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
  38. Install the oil pan and install the 2 oil pan bolts finger-tight.
    Fig 32: Locating Oil Pan Silicone Gasket And Sealant Bead
    G06390204Courtesy of FORD MOTOR CO.
  39. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
    Fig 33: Aligning Front Surface Using Suitable Straightedge
    G06390205Courtesy of FORD MOTOR CO.
  40. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 34: Identifying Oil Pan Bolts Tightening Sequence
      G06390206Courtesy of FORD MOTOR CO.
  41. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 35: Locating Cylinder Head Alignment Dowels
    G06390207Courtesy of FORD MOTOR CO.
    42. 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.
  42. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
    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.
  43. Apply silicone gasket and sealant to the locations shown.
    Fig 36: Identifying Silicone Gasket And Sealant Application Points
    G06390208Courtesy of FORD MOTOR CO.
  44. Install a new head gasket.
    Fig 37: Locating Head Gasket
    G06390209Courtesy of FORD MOTOR CO.
    45. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
  45. 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 (133 lb-in).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
      Fig 38: Identifying Cylinder Head Bolts Tightening Sequence
      G06390210Courtesy of FORD MOTOR CO.
    46. NOTE: Coat the valve tappets with clean engine oil prior to installation.
  46. Install the valve tappets.
    47. 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.
  47. 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 one turn at a time until tight.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (142 lb-in).
      Fig 39: Identifying Bearing Cap Bolts Tightening Sequence
      G06390211Courtesy of FORD MOTOR CO.
  48. Install the Variable Camshaft Timing (VCT) system oil filter and plug in the intake camshaft thrust cap.
    • Tighten to 17 Nm (150 lb-in).
      Fig 40: Locating Plug And VCT System Oil Filter
      G06390212Courtesy of FORD MOTOR CO.
  49. Install the VCT  solenoid and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 41: Locating Bolt And Variable Camshaft Timing Solenoid
      G06390213Courtesy of FORD MOTOR CO.
    50. NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
  50. 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.
      Fig 42: Locating Crankshaft Sprocket
      G06390214Courtesy of FORD MOTOR CO.
  51. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 43: Locating Oil Pump Chain, Sprocket And Bolt
      G06390215Courtesy of FORD MOTOR CO.
  52. Install the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 44: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
      G06390216Courtesy of FORD MOTOR CO.
  53. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 45: Locating Oil Pump Drive Chain Tensioner, Bolt And Tensioner Spring
      G06390217Courtesy of FORD MOTOR CO.
    54. NOTE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    Fig 46: Identifying Camshaft Alignment Plate Installation Position
    G06390218Courtesy of FORD MOTOR CO.
  54. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
  55. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    Fig 47: Locating Camshaft Sprockets And Bolts
    G06390219Courtesy of FORD MOTOR CO.
  56. Install the LH timing chain guide and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 48: Locating LH Timing Chain Guide Bolts
      G06390220Courtesy of FORD MOTOR CO.
  57. Install the timing chain.
    Fig 49: Locating Timing Chain
    G06390221Courtesy of FORD MOTOR CO.
  58. Install the RH timing chain guide.
    Fig 50: Locating Timing Chain Guide
    G06390222Courtesy of FORD MOTOR CO.
    NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
    59. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    Fig 51: Compressing Timing Chain Tensioner Plunger
    G06390223Courtesy of FORD MOTOR CO.
  59. Using the edge of a vise, compress the timing chain tensioner plunger.
  60. Using a small pick, push back and hold the ratchet mechanism.
    Fig 52: Holding Ratchet Mechanism Using Small Pick
    G06390224Courtesy of FORD MOTOR CO.
  61. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 53: Pushing Ratchet Arm Back Into Tensioner Housing
    G06390225Courtesy of FORD MOTOR CO.
  62. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 54: Installing Paper Clip Into Hole In Tensioner Housing
    G06390226Courtesy of FORD MOTOR CO.
  63. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
      Fig 55: Locating Timing Chain Tensioner And Bolts
      G06390227Courtesy of FORD MOTOR CO.
    64. NOTE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  64. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • Tighten to 72 Nm (53 lb-ft).
      Fig 56: Locating Camshaft Bolts
      G06390228Courtesy of FORD MOTOR CO.
    65. 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.
  65. Clean and inspect the mounting surfaces of the engine and the front cover.
    66. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    Fig 57: Applying Silicone Gasket And Sealant On Engine Front Cover
    G06390229Courtesy of FORD MOTOR CO.
  66. 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.
  67. 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).
      Fig 58: Identifying Engine Front Cover Bolts Tightening Sequence
      G06390230Courtesy of FORD MOTOR CO.
    68. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer.
    NOTE: Lubricate the oil seal with clean engine oil.
    Fig 59: Installing Crankshaft Front Oil Seal Using Special Tool
    G06390231Courtesy of FORD MOTOR CO.
  68. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
    69. NOTE: Do not install the crankshaft pulley bolt at this time.
    NOTE: Apply clean engine oil on the seal area before installing.
    Fig 60: Locating Crankshaft Pulley Bolt
    G06390232Courtesy of FORD MOTOR CO.
  69. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    70. NOTE: Only hand-tighten the 6-mm bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
    Fig 61: Locating Crankshaft Pulley Bolt
    G06390233Courtesy of FORD MOTOR CO.
  70. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
    71. 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 Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.
    NOTE: Do not reuse the crankshaft pulley bolt.
  71. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool 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 (one-fourth turn).
      Fig 62: Locating Crankshaft Pulley Bolt
      G06390234Courtesy of FORD MOTOR CO.
  72. Remove the 6 mm x 18 mm bolt.
    Fig 63: Locating Crankshaft Pulley Bolt
    G06390235Courtesy of FORD MOTOR CO.
  73. Remove the Crankshaft TDC  Timing Peg.
    Fig 64: Identifying Crankshaft TDC Timing Peg
    G06390236Courtesy of FORD MOTOR CO.
  74. Remove the Camshaft Alignment Plate.
    Fig 65: Identifying Camshaft Alignment Plate Installation Position
    G06390237Courtesy of FORD MOTOR CO.
    75. NOTE: Only turn the engine in the normal direction of rotation.
  75. Turn the crankshaft clockwise one and three-fourths turns.
  76. Install the Crankshaft TDC  Timing Peg.
    Fig 66: Identifying Crankshaft TDC Timing Peg
    G06390238Courtesy of FORD MOTOR CO.
    77. NOTE: Only turn the engine in the normal direction of rotation.
    Fig 67: Installing Crankshaft TDC Timing Peg
    G06390239Courtesy of FORD MOTOR CO.
  77. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC  Timing Peg.
    78. NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
  78. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected.
      Fig 68: Locating Crankshaft Pulley Bolt
      G06390240Courtesy of FORD MOTOR CO.
  79. Install the Camshaft Alignment Plate to check the position of the camshafts.
    • If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
      Fig 69: Identifying Camshaft Alignment Plate Installation Position
      G06390241Courtesy of FORD MOTOR CO.
  80. Remove the Camshaft Alignment Plate.
    Fig 70: Identifying Camshaft Alignment Plate Installation Position
    G06390242Courtesy of FORD MOTOR CO.
  81. Install the Crankshaft Position (CKP) sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
      Fig 71: Locating Bolts And CKP Sensor
      G06390243Courtesy of FORD MOTOR CO.
  82. Using the Crankshaft Sensor Aligner, adjust the CKP  sensor.
    • Tighten the 2 CKP  bolts to 7 Nm (62 lb-in).
      Fig 72: Identifying Crankshaft Sensor Aligner
      G06390244Courtesy of FORD MOTOR CO.
  83. Remove the 6 mm x 18 mm bolt.
    Fig 73: Locating Crankshaft Pulley Bolt
    G06390245Courtesy of FORD MOTOR CO.
  84. Remove the Crankshaft TDC  Timing Peg.
    Fig 74: Identifying Crankshaft TDC Timing Peg
    G06390246Courtesy of FORD MOTOR CO.
  85. Install the engine plug bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 75: Locating Engine Plug Bolt
      G06390247Courtesy of FORD MOTOR CO.
    86. 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.
  86. Clean the valve cover gasket surface with metal surface prep.
  87. Apply silicone gasket and sealant to the locations shown.
    Fig 76: Locating Silicone Gasket And Sealant Applying Locations
    G06390248Courtesy of FORD MOTOR CO.
    88. 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.
  88. Install the valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
      Fig 77: Identifying Valve Cover Bolts Tightening Sequence
      G06390249Courtesy of FORD MOTOR CO.
    89. NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
  89. Install the Cylinder Head Temperature (CHT) sensor and the spark plugs.
    • Tighten the CHT  sensor to 12 Nm (106 lb-in).
    • Tighten the spark plugs to 12 Nm (106 lb-in).
      Fig 78: Locating Cylinder Head Temperature Sensor
      G06390250Courtesy of FORD MOTOR CO.
    90. NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.
    Fig 79: Locating Oil Level Indicator
    G06390251Courtesy of FORD MOTOR CO.
  90. Install the oil level indicator.
    91. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
  91. Install the 4 coil-on-plugs and the 4 bolts. Install the crankshaft vent tube.
    • Tighten to 8 Nm (71 lb-in).
      Fig 80: Locating Coil-On-Plugs Stud Bolts
      G06390252Courtesy of FORD MOTOR CO.
  92. Install the engine cover studs.
    Fig 81: Locating Engine Cover Studs
    G06390253Courtesy of FORD MOTOR CO.
  93. Install the crankshaft vent tube.
    Fig 82: Locating Crankshaft Vent Tube
    G06390254Courtesy of FORD MOTOR CO.
  94. If equipped, install the block heater.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 83: Locating Block Heater
      G06390255Courtesy of FORD MOTOR CO.
    95. NOTE: Clean the gasket mating surfaces with metal surface prep.
  95. Install the oil filter adapter with a new gasket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 84: Locating Oil Filter Adapter Bolts
      G06390256Courtesy of FORD MOTOR CO.
  96. Install the crankcase vent oil separator and the 8 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 85: Locating Bolts And Crankcase Vent Oil Separator
      G06390257Courtesy of FORD MOTOR CO.
    97. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
  97. Install the KS  and the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 86: Locating Knock Sensor Ground Bolt
      G06390258Courtesy of FORD MOTOR CO.
  98. Install the coolant hose.
    Fig 87: Locating Coolant Hose
    G06390259Courtesy of FORD MOTOR CO.
  99. Install the coolant hose.
    Fig 88: Locating Coolant Hose
    G06390260Courtesy of FORD MOTOR CO.
    100. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
  100. Install the thermostat housing.
    • Tighten to 10 Nm (89 lb-in).
      Fig 89: Locating Thermostat Housing Bolts
      G06390261Courtesy of FORD MOTOR CO.
    101. NOTE: Make sure the coolant pump is correctly seated to the engine block before installing and tightening the fasteners, or damage to the coolant pump may occur.
    NOTE: Clean the coolant pump mating surface with metal surface cleaner.
    NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
  101. Install the new O-ring, coolant pump and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 90: Locating Coolant Pump Bolts
      G06390262Courtesy of FORD MOTOR CO.
  102. Install the coolant pump pulley and bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 91: Locating Bolts And Coolant Pump Pulley
      G06390263Courtesy of FORD MOTOR CO.
  103. Position the engine control wiring harness on the engine.
  104. Attach the wiring harness retainer to the valve cover and stud bolt.
    • Connect the EGR valve electrical connector.
      Fig 92: Locating EGR Valve Electrical Connector
      G06390264Courtesy of FORD MOTOR CO.
  105. Connect the CHT  sensor and install the rubber boot.
    Fig 93: Locating Rubber Boot And Cylinder Head Temperature Sensor Electrical Connector
    G06390265Courtesy of FORD MOTOR CO.
  106. Connect the 4 coil-on-plug electrical connectors.
    Fig 94: Locating Coil-On-Plug Electrical Connectors
    G06390266Courtesy of FORD MOTOR CO.
    107. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
  107. Install new fuel injector O-rings.
    • Separate the fuel injectors from the fuel rail.
    • Remove and discard the fuel injector O-rings.
    • Install new O-rings and lubricate with clean engine oil.
    • Install the fuel injectors onto the fuel rail.
      Fig 95: Locating Fuel Injector O-Ring Seals
      G06390267Courtesy of FORD MOTOR CO.
  108. Install the fuel rail with the fuel injectors and stud bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 96: Locating Stud Bolts
      G06390268Courtesy of FORD MOTOR CO.
  109. Install the radio capacitor and the nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 97: Locating Nut And Radio Capacitor
      G06390269Courtesy of FORD MOTOR CO.
  110. Install the fuel rail insulator.
    Fig 98: Locating Fuel Rail Insulator
    G06390270Courtesy of FORD MOTOR CO.
  111. Position the high-voltage wiring harness and attach the 2 wiring harness retainers to the ignition coil stud bolts.
    Fig 99: Locating Wiring Harness Retainers
    G06390271Courtesy of FORD MOTOR CO.
  112. Connect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
    Fig 100: Locating Fuel Injector Electrical Connectors, Radio Capacitor Electrical Connector And CMP Sensor Electrical Connector
    G06390272Courtesy of FORD MOTOR CO.
  113. Install the EGR tube.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 101: Identifying EGR Tube
      G06390273Courtesy of FORD MOTOR CO.
    114. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    Fig 102: Locating Crankcase Vent Oil Separator Tube
    G06390274Courtesy of FORD MOTOR CO.
  114. Position the intake manifold and connect the PCV hose.
    115. NOTE: Inspect and install new intake manifold gaskets, if necessary.
    NOTE: The cylinder head side of the intake manifold is showing bolt location.
  115. Install the intake manifold gasket, intake manifold and 7 bolts.
    • Tighten to 18 Nm (159 lb-in).
      Fig 103: Locating Intake Manifold Bolts
      G06390275Courtesy of FORD MOTOR CO.
  116. Attach the 3 wire harness pin-type retainers to the intake manifold.
    Fig 104: Locating Wire Harness Pin-Type Retainers
    G06390276Courtesy of FORD MOTOR CO.
  117. Install the vacuum pump assembly, the nut and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 105: Locating Bolts, Nut And Vacuum Pump Assembly
      G06390277Courtesy of FORD MOTOR CO.
  118. Connect the vacuum hose to the intake manifold.
    Fig 106: Locating Vacuum Hose
    G06390278Courtesy of FORD MOTOR CO.
  119. Connect the EGR coolant hose and the auxiliary coolant pump hose.
    Fig 107: Locating EGR Coolant Hose And Auxiliary Coolant Pump Hose
    G06390279Courtesy of FORD MOTOR CO.
  120. Connect the auxiliary coolant pump hose and the upper radiator hose.
    Fig 108: Locating Auxiliary Coolant Pump Hose And Upper Radiator Hose
    G06390280Courtesy of FORD MOTOR CO.
  121. Attach the 2 wiring harness retainers to the fuel rail and the one to the valve cover.
    Fig 109: Locating Wiring Harness Retainers
    G06390281Courtesy of FORD MOTOR CO.
  122. Connect the VCT  electrical connector and attach the wiring harness retainer to the valve cover stud bolt.
    Fig 110: Locating VCT Oil Control Solenoid Electrical Connector And Wiring Harness Retainer
    G06390282Courtesy of FORD MOTOR CO.
  123. Install the A/C compressor bracket and 2 bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 111: Locating A/C Compressor Bracket Bolts
      G06390283Courtesy of FORD MOTOR CO.
  124. Install the A/C compressor and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 112: Locating A/C Compressor Bolts
      G06390284Courtesy of FORD MOTOR CO.
  125. Connect the A/C compressor electrical connector.
    Fig 113: Locating A/C Compressor Electrical Connector
    G06390285Courtesy of FORD MOTOR CO.
  126. Attach the pin-type retainer to the intake manifold and connect the KS  electrical connector.
    Fig 114: Locating Knock Sensor Electrical Connector And Electrical Connector Pin-Type Retainer
    G06390286Courtesy of FORD MOTOR CO.
  127. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
    Fig 115: Locating Manifold Absolute Pressure Sensor Electrical Connector
    G06390287Courtesy of FORD MOTOR CO.
  128. Connect the Engine Oil Pressure (EOP) switch electrical connector.
    Fig 116: Locating Engine Oil Pressure Switch Electrical Connector
    G06390288Courtesy of FORD MOTOR CO.
  129. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 117: Locating Evaporative Emission Canister Purge Valve Electrical Connector
    G06390289Courtesy of FORD MOTOR CO.
  130. Connect the electronic throttle control electrical connector.
    Fig 118: Locating Electronic Throttle Control Electrical Connector
    G06390290Courtesy of FORD MOTOR CO.
  131. Install the accessory drive belt tensioner.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 119: Locating Accessory Drive Belt Tensioner
      G06390291Courtesy of FORD MOTOR CO.
  132. Attach the vehicle high-voltage electrical system electrical connector retainer to the accessory drive belt tensioner.
    Fig 120: Locating Vehicle High-Voltage Electrical System Electrical Connector
    G06390292Courtesy of FORD MOTOR CO.
  133. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
    Fig 121: Rotating Accessory Drive Belt Tensioner
    G06390293Courtesy of FORD MOTOR CO.
  134. Install 7 new exhaust manifold studs in the cylinder head.
    • Tighten to 17 Nm (150 lb-in).
      Fig 122: Locating Exhaust Manifold Studs
      G06390294Courtesy of FORD MOTOR CO.
  135. Install the new exhaust manifold gasket on the engine.
    136. NOTE: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
    NOTE: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
  136. Position the catalytic converter and tighten the 7 new nuts in the sequence shown in 2 stages:
    • Stage 1: Tighten to 48 Nm (35 lb-ft).
    • Stage 2: Tighten to 48 Nm (35 lb-ft).
      Fig 123: Locating Catalytic Converter Manifold Nuts
      G06390295Courtesy of FORD MOTOR CO.
  137. Attach the 2 wiring harness pin-type retainers.
    Fig 124: Locating Wiring Harness Pin-Type Retainers
    G06390296Courtesy of FORD MOTOR CO.
  138. Install the engine wiring harness connector bracket.
    • Tighten to 15 Nm (133 lb-in).
      Fig 125: Locating Bolt And Engine Wiring Harness Connector Bracket
      G06390297Courtesy of FORD MOTOR CO.
  139. Connect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 126: Locating Crankshaft Position Sensor Electrical Connector
    G06390298Courtesy of FORD MOTOR CO.
  140. Connect the Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 127: Locating Catalyst Monitor Sensor Electrical Connector
    G06390299Courtesy of FORD MOTOR CO.
  141. Connect the Heated Oxygen Sensor (HO2S) connector. Attach the connector to the engine wiring harness connector bracket.
    Fig 128: Locating Locking Tab And Heated Oxygen Sensor Electrical Connector
    G06390300Courtesy of FORD MOTOR CO.
  142. Using the Heavy Duty Floor Crane and the Spreader Bar, remove the engine from the engine stand.
    143. NOTE: Special bolts are used for installation. Do not use standard bolts.
  143. 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).
      Fig 129: Identifying Flexplate Bolts Tightening Sequence
      G06390301Courtesy of FORD MOTOR CO.
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