Section 516 (Engine - 4.6L & 5.4L): Assembly: Engine: Assembly

ALL ENGINES 

1. Record the main bearing code found on the front of the engine block.
   Fig 1: Identifying Main Bearing Code (1 Of 2)

   Courtesy of FORD MOTOR CO.
2. Record the main bearing code found on the back of the crankshaft
   Fig 2: Identifying Main Bearing Code (2 Of 2)

   Courtesy of FORD MOTOR CO.

BEARING SELECT FIT CHART, STANDARD BEARINGS 

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 two 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 3: Bearing Select Fit Chart (Standard Bearings)

   Courtesy of FORD MOTOR CO.

BEARING SELECT FIT CHART, OVERSIZE BEARINGS 

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 4: Bearing Select Fit Chart (Oversize Bearings)

   Courtesy of FORD MOTOR CO.

WINDSOR ENGINE (5.4L) 

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 two steps.
Fig 5: 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 6: Installing Rear Crankshaft Upper Thrust Washer
Courtesy of FORD MOTOR CO.
7. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
Fig 7: Installing Front Crankshaft Upper Thrust Washer
Courtesy of FORD MOTOR CO.
8. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).
Fig 8: Installing Lower Crankshaft Thrust Washer
Courtesy of FORD MOTOR CO.
9. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
10. 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 tap into place using a plastic or dead-blow hammer.
    Fig 9: Installing Crankshaft Lower Main Bearings Into Main Bearing Caps

    Courtesy of FORD MOTOR CO.
11. Install the dowel pins so the flat sides face the crankshaft.
    Fig 10: Installing Dowel Pins

    Courtesy of FORD MOTOR CO.
12. Install the vertical main bearing cap fasteners and tighten in the sequence shown.
    • Tighten to 40 N.m (30 lb-ft).
    • Tighten an additional 90 degrees.
    Fig 11: Identifying Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
13. Install the side bolts and tighten them in the sequence shown.
    • Tighten to 30 N.m (22 lb-ft).
    • Tighten an additional 90 degrees.
    Fig 12: Installing Side Bolts

    Courtesy of FORD MOTOR CO.

ROMEO ENGINE (4.6L) 

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.
14. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
15. Install the crankshaft onto the upper crankshaft main bearings.
    Fig 13: Installing Crankshaft Onto Upper Crankshaft Main Bearings

    Courtesy of FORD MOTOR CO.
NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
Fig 14: Installing Crankshaft Upper Thrust Washer
Courtesy of FORD MOTOR CO.
16. 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 15: Installing Rear Main Bearing Cap
Courtesy of FORD MOTOR CO.
17. Install the rear main bearing cap.
18. 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 tap into place using a plastic or dead-blow hammer.
    Fig 16: Installing Crankshaft Lower Main Bearings Into Main Bearing Caps

    Courtesy of FORD MOTOR CO.
19. Install the vertical main bearing cap fasteners and tighten in the sequence shown.
    • Tighten to 40 N.m (30 lb-ft).
    • Tighten an additional 90 degrees.
    Fig 17: Identifying Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
20. Tighten the jack screws against the cylinder block in the sequence shown.
    • Tighten to 5 N.m (44 lb-in).
    • Tighten to 10 N.m (89 lb-in).
    Fig 18: Tightening Jack Screws

    Courtesy of FORD MOTOR CO.
21. Install the side bolts and tighten them in the sequence shown.
    Fig 19: Installing Side Bolts

    Courtesy of FORD MOTOR CO.

ALL ENGINES 

CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: The next three step are for all eight connecting rods, rod caps rod cap and pistons is shown.
NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.
Fig 20: Installing Piston And Connecting Rod
Courtesy of FORD MOTOR CO.
22. 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 21: Removing Connecting Rod Installer
Courtesy of FORD MOTOR CO.
23. 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.
24. Position the lower bearing and connecting rod, and install the new bolts loosely.
NOTE: Main bearing caps are removed for clarity.
Fig 22: Identifying Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
25. Tighten the bolts in two stages, using the sequence shown.
    • Stage 1: Tighten to 43 N.m (32 lb-ft).
    • Stage 2: Tighten an additional 105 degrees.
26. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
    Fig 23: Positioning Oil Pump

    Courtesy of FORD MOTOR CO.
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.
Fig 24: Positioning Head Gasket Over Dowel Pins
Courtesy of FORD MOTOR CO.
27. Position the head gasket over the dowel pins.
    • RH is shown: LH is similar.
28. Rotate the crankshaft until the crankshaft keyway points toward the top of the engine (12 o'clock).
    Fig 25: Identifying Crankshaft Keyway Points

    Courtesy of FORD MOTOR CO.
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.
Fig 26: Positioning Cylinder Head Over Dowels
Courtesy of FORD MOTOR CO.
29. Position the cylinder head over the dowels and head gasket and install the cylinder head bolts loosely.
    • RH is shown: LH is similar.
30. Tighten the bolts in three stages, in the sequence shown.

    RH is shown; LH is similar

    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
    Fig 27: Cylinder Head Bolt Tightening Sequence

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil.
Fig 28: Installing Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
31. 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.
32. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
    Fig 29: Installing RH Exhaust Manifold Gaskets And Exhaust Manifold

    Courtesy of FORD MOTOR CO.
33. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
    Fig 30: Installing LH Exhaust Manifold And Exhaust Manifold Gaskets

    Courtesy of FORD MOTOR CO.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
Fig 31: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
34. Compress the tensioner plunger, using a vise.
35. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 32: Installing Retaining Clip On Tensioner

    Courtesy of FORD MOTOR CO.
36. Remove the tensioner from the vise.

WINDSOR ENGINE (5.4L) 

37. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
    Fig 33: Identifying Mark Two Links

    Courtesy of FORD MOTOR CO.
38. Install the timing chain guides.
    Fig 34: Installing Timing Chain Guides

    Courtesy of FORD MOTOR CO.
CAUTION: Do not turn the engine over with the special tool or damage to the camshaft sprocket or the bolt can occur.
Fig 35: Installing Special Tool
Courtesy of FORD MOTOR CO.
39. Install the special tool.
40. Pre-position the camshafts.
    1. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
    2. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.
    Fig 36: Identifying Timing Mark

    Courtesy of FORD MOTOR CO.
CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur.
NOTE: The number one piston 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 37: Positioning Crankshaft
Courtesy of FORD MOTOR CO.
41. Position the crankshaft so the number one cylinder is at TDC with the special tool.
42. Remove the Crankshaft Holding Tool.
43. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 38: Installing Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
44. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
    Fig 39: Aligning Timing Mark

    Courtesy of FORD MOTOR CO.
NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
NOTE: If necessary, use the Camshaft Alignment Set to adjust the camshaft sprocket slightly to obtain timing mark alignment.
Fig 40: Identifying Timing Mark
Courtesy of FORD MOTOR CO.
45. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Fig 41: Installing LH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
46. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
47. Remove the retaining clip from the LH timing chain tensioner.
    Fig 42: Removing Retaining Clip From LH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
48. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
    Fig 43: Positioning Lower End Of RH (Outer) Timing Chain On Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
NOTE: If necessary, use the Camshaft Alignment Set to adjust the camshaft sprocket slightly to obtain timing mark alignment.
Fig 44: Aligning Timing Mark
Courtesy of FORD MOTOR CO.
49. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
50. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 45: Installing RH Timing Chain Tensioner Arm On Dowel Pin

    Courtesy of FORD MOTOR CO.
51. Remove the retaining clip from the RH timing chain tensioner.
    Fig 46: Removing Retaining Clip From RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
52. As a post-check, verify correct alignment of all timing marks.
    Fig 47: Checking Timing Marks

    Courtesy of FORD MOTOR CO.

ROMEO ENGINE (4.6L) 

53. 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 48: Identifying Mark Link

    Courtesy of FORD MOTOR CO.
54. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 49: Identifying Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
55. 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.
    Fig 50: Installing Timing Chain Guides

    Courtesy of FORD MOTOR CO.
56. 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 51: Identifying Timing Mark

    Courtesy of FORD MOTOR CO.
CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and valve damage can occur.
NOTE: The number one 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 52: Position Crankshaft With Special Tool
Courtesy of FORD MOTOR CO.
57. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
58. Remove the Crankshaft Holding Tool.
59. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 53: Aligning Copper (Marked) Link With Timing Mark On Sprocket

    Courtesy of FORD MOTOR CO.
60. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 54: Aligning Copper (Marked) Link With Timing Marks On Sprocket

    Courtesy of FORD MOTOR CO.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Fig 55: Positioning LH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
61. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
62. Remove the retaining clip from the LH timing chain tensioner.
    Fig 56: Removing Retaining Clip From LH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
63. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 57: Aligning Copper (Marked) Link With Timing Mark On Sprocket

    Courtesy of FORD MOTOR CO.
64. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 58: Installing RH Timing Chain On Camshaft Sprocket

    Courtesy of FORD MOTOR CO.
65. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 59: Installing RH Timing Chain Tensioner Arm On Dowel Pin

    Courtesy of FORD MOTOR CO.
66. Remove the retaining clip from the RH timing chain tensioner.
    Fig 60: Removing Retaining Clip From RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
67. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    Fig 61: Checking Timing Mark

    Courtesy of FORD MOTOR CO.

ALL ENGINES 

68. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 62: Installing Special Tool Between Valve Spring Coils

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the camshaft roller followers using clean engine oil.
Fig 63: Installing Camshaft Roller
Courtesy of FORD MOTOR CO.
69. Install the camshaft roller followers.
    1. Install the special tool.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original locations.
70. Remove the special tool.
    Fig 64: Removing Special Tool

    Courtesy of FORD MOTOR CO.
71. Install the crankshaft sensor ring on the crankshaft.
    Fig 65: Installing Crankshaft Sensor Ring On Crankshaft

    Courtesy of FORD MOTOR CO.
NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 66: Applying Bead Of Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
72. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block sealing surfaces, at the locations shown.
73. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 67: Installing Engine Front Cover

    Courtesy of FORD MOTOR CO.

ROMEO ENGINE (4.6L) 

74. Tighten the front cover fasteners in the sequence shown to 25 N.m (18 lb-ft).
    Fig 68: Identifying Front Cover Fasteners Tightening Sequence (Romeo Engine 4.6L)

    Courtesy of FORD MOTOR CO.
75. Tighten the engine front cover fasteners in sequence in three stages.

    Stage 1: Tighten fasteners 1 through 5 to 25 N.m (18 lb-ft).

    Stage 2: Tighten fasteners 6 and 7 to 48 N.m (35 lb-ft).

    Stage 3: Tighten fasteners 8 through 15 to 48 N.m (35 lb-ft).

    Fig 69: Identifying Front Cover Fasteners Tightening Sequence (Windsor Engine 5.4L) (Items 1-11)

    Courtesy of FORD MOTOR CO.
    Fig 70: Identifying Front Cover Fasteners Tightening Sequence (Windsor Engine 5.4L) (Items 12-15)

    Courtesy of FORD MOTOR CO.

ALL ENGINES 

76. Install the oil pump screen and pickup tube spacer.
    Fig 71: 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 72: Positioning Oil Pump Screen
Courtesy of FORD MOTOR CO.
77. Position the oil pump screen and pickup tube and install the bolts.

ROMEO ENGINE (4.6L) 

78. Position a new gasket and the oil filter adapter. Install the nuts and bolts.
    Fig 73: Positioning New Gasket And Oil Filter Adapter

    Courtesy of FORD MOTOR CO.

WINDSOR ENGINE (5.4L) 

79. Position a new gasket and the oil filter adapter. Install the bolts and nut.
    Fig 74: Installing Bolts And Nut

    Courtesy of FORD MOTOR CO.
80. Position the engine mounts to the cylinder block and install the six bolts.
    Fig 75: Installing Six Bolts

    Courtesy of FORD MOTOR CO.
81. Position the belt idler pulley and install the bolt.
    Fig 76: Installing Belt Idler Pulley

    Courtesy of FORD MOTOR CO.
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 77: Installing Bolts
Courtesy of FORD MOTOR CO.
82. Install the coolant pump.
    1. Lubricate the new O-ring seal using 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.
83. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
    Fig 78: Lubricating Engine Front Cover

    Courtesy of FORD MOTOR CO.
84. Use the special tools to install the crankshaft front seal into the engine front cover.
    Fig 79: Installing Crankshaft Front Seal Into Engine Front Cover

    Courtesy of FORD MOTOR CO.
NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 80: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
85. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
86. Use the special tool to install the crankshaft pulley.
    Fig 81: Installing Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
87. Loosely install a new crankshaft pulley bolt. Tighten the bolt in four stages.
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 82: Installing Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
88. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 83: Positioning Coolant Pump Pulley On Coolant Pump

    Courtesy of FORD MOTOR CO.
NOTE: The front lower hole in the power steering pump is not used.
Fig 84: Positioning Power Steering Pump
Courtesy of FORD MOTOR CO.
89. Position the power steering pump and install the bolts.
90. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    Fig 85: Installing Valve Cover Gasket

    Courtesy of FORD MOTOR CO.
NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 86: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
91. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
92. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 87: Positioning LH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.

ROMEO ENGINE (4.6L) 

93. Tighten the bolts in the sequence shown.
    Fig 88: Identifying Bolts Tightening Sequence (Romeo Engine 4.6L)

    Courtesy of FORD MOTOR CO.

WINDSOR ENGINE (5.4L) 

94. Tighten the bolts in the sequence shown.
    Fig 89: Identifying Bolts Tightening Sequence (Windsor Engine 5.4L)

    Courtesy of FORD MOTOR CO.

ALL ENGINES 

95. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    Fig 90: Applying Instant Adhesive Completely Around Gasket Groove In Rh Valve Cover

    Courtesy of FORD MOTOR CO.
NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 91: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
96. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
97. Position the RH valve cover and gasket on the cylinder head. Install the bolts loosely.
    Fig 92: Positioning RH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.

ROMEO ENGINE (4.6L) 

98. Tighten the bolts in the sequence shown.
    Fig 93: Identifying Bolts Tightening Sequence (Romeo Engine 4.6L)

    Courtesy of FORD MOTOR CO.
99. Tighten the bolts in the sequence shown.
    Fig 94: Identifying Bolts Tightening Sequence (Windsor Engine 5.4L)

    Courtesy of FORD MOTOR CO.

ALL ENGINES 

100. Install the crankcase ventilation tube on the LH valve cover.
     Fig 95: Installing Crankcase Ventilation Tube On LH Valve Cover

     Courtesy of FORD MOTOR CO.
NOTE: On 4.6L engines it is necessary to twist the positive crankcase ventilation (PCV) valve approximately 180 degrees to secure it in the RH valve cover.
Fig 96: Installing PCV Valve And Hose In RH Valve Cover
Courtesy of FORD MOTOR CO.
101. Install the PCV valve and hose in the RH valve cover.
NOTE: Typical RH shown, LH similar.
Fig 97: Installing Radio Frequency Interference Capacitors
Courtesy of FORD MOTOR CO.
102. Install the radio frequency interference capacitors.
103. Install the engine control sensor wiring.
104. Install the special tool.
     Fig 98: Installing Special Tool

     Courtesy of FORD MOTOR CO.
NOTE: The oil level indicator and tube are removed for clarity.
Fig 99: Installing Special Tool
Courtesy of FORD MOTOR CO.
105. Install the special tool.
106. Install the special tool and remove the engine from the work stand.
     Fig 100: Removing Engine From Work Stand With Special Tool

     Courtesy of FORD MOTOR CO.
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.
107. Inspect the 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 four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 101: Apply Bead Of Silicone Gasket And Sealant Around Rear Oil Seal Retainer Sealing Surface
Courtesy of FORD MOTOR CO.
108. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
109. Install the rear oil seal retainer plate and loosely install the six bolts.
     Fig 102: Installing Rear Oil Seal Retainer Plate

     Courtesy of FORD MOTOR CO.
110. Tighten the bolts in the sequence shown.
     Fig 103: Identifying Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
111. Install the oil drain plug before installing the oil pan.
     Fig 104: Installing Oil Drain Plug

     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.
112. 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 the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 105: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
113. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 106: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
114. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
115. Install the oil pan gasket and the oil pan and loosely install the bolts.
     Fig 107: Installing Oil Pan Gasket And Oil Pan

     Courtesy of FORD MOTOR CO.
116. Tighten the bolts in three stages, in the sequence shown.
     • Stage 1: Tighten to 2 N.m (18 lb-in).
     • Stage 2: Tighten to 20 N.m (15 lb-ft).
     • Stage 3: Tighten an additional 90 degrees.
     Fig 108: Oil Pan Bolt Tightening Sequence

     Courtesy of FORD MOTOR CO.
117. Lower the engine onto wooden blocks.
118. Remove the special tool.
     Fig 109: Removing Special Tool

     Courtesy of FORD MOTOR CO.
NOTE: The oil level indicator and tube are removed for clarity.
Fig 110: Removing Special Tool
Courtesy of FORD MOTOR CO.
119. Remove the special tool.
120. Install the special tool and raise the engine.
     Fig 111: Installing Special Tool

     Courtesy of FORD MOTOR CO.
121. Make sure the special tool does not extend beyond the back of the engine block
     Fig 112: Identifying Back Of Engine Block

     Courtesy of FORD MOTOR CO.
122. Install the oil level indicator tube nut and insert the oil level indicator.
     Fig 113: Installing Oil Level Indicator Tube

     Courtesy of FORD MOTOR CO.
NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Fig 114: Installing Crankshaft Rear Seal
Courtesy of FORD MOTOR CO.
123. Using the special tools, install a new crankshaft rear seal.
124. Using the special tools, install the crankshaft rear oil slinger.
     Fig 115: Installing Crankshaft Rear Oil Slinger

     Courtesy of FORD MOTOR CO.

ROMEO ENGINE (4.6L) 

125. Install the flexplate and bolts. Tighten the bolts in the sequence shown.
     Fig 116: Installing Flexplate Bolts (Romeo Engine 4.6L)

     Courtesy of FORD MOTOR CO.

WINDSOR ENGINE (5.4L) 

126. Install the flexplate and bolts. Tighten the bolts in the sequence shown.
     Fig 117: Installing Flexplate Bolts (Windsor Engine 5.4L)

     Courtesy of FORD MOTOR CO.