Engine - Lower End

WARNING: This page is about a different car, the 2012 Ford Pickup and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Exploded View Of Engine - Lower End

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	W503276	Crankshaft Position (CKP) sensor bolt
2	6C315	CKP sensor
3	6K301	Crankshaft rear seal retainer plate
4	N806155	Crankshaft rear seal retainer plate bolt (10 required)
5	6375	Flexplate
6	6379	Flexplate bolt (8 required)
7	6375	Flywheel bolt (8 required)
8	6379	Flywheel
9	7120	Pilot bearing
10	12A227	Ignition pulse ring
11	6701	Crankshaft rear seal
12	6881	Oil filter adapter
13	6A642	Oil cooler
14	6731	Oil filter
15	9278	Engine Oil Pressure (EOP) switch
16	W713261	Oil filter adapter bolt (4 required)
17	6C357	Crankshaft main bearing cap side bolt (10 required)
18	6A341	Crankshaft thrust washer - upper
19	6303	Crankshaft
20	6D309B	Crankshaft thrust washer - lower
21	6345	Crankshaft main bearing cap bolt (9 required)
22	6K258	Crankshaft main bearing cap stud bolt
23	6345	Crankshaft main bearing cap bolt (10 required)
24	6675	Oil pan
25	W503276	Oil pan bolt (20 required)
26	6710	Oil pan gasket
27	6325	Crankshaft main bearing cap (5 required)
28	6D309A	Crankshaft bearing - lower (4 required)
29	6D309A	Crankshaft bearing - upper (5 required)
30	6K868	Piston oil cooler valve (4 required)
31	W701706	Oil pump screen and pickup tube nut
32	W503276	Oil pump screen and pickup tube bolt (2 required)
33	6622	Oil pump screen and pickup tube
34	6010	Cylinder block
35	-	Piston and connecting rod assembly (8 required)

Record the main bearing code found on the front of the engine block.

Fig 2: Locating Main Bearing Code On Front Of Engine Block
Courtesy of FORD MOTOR CO.
Record the main bearing code found on the back of the crankshaft.

Fig 3: Locating Main Bearing Code On Back Of Crankshaft
Courtesy of FORD MOTOR CO.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
- Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
- Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 1 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 4 main bearings.
Fig 4: Bearing Select Fit Chart (Standard Bearings)
Courtesy of FORD MOTOR CO.
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 5: Bearing Select Fit Chart (Oversize Bearings)
Courtesy of FORD MOTOR CO.
Position the 4 piston oil cooler valves with the bolt boss facing toward the rear of the cylinder block and install the 4 bolts in 2 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.
Fig 6: Locating Piston Oil Cooler Valves And Bolts
Courtesy of FORD MOTOR CO.

NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

Fig 7: Locating Crankshaft Upper Main Bearings

Courtesy of FORD MOTOR CO.

Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.

NOTE: Do not allow the crankshaft to come into contact with the piston oil cooler valves during assembly or engine damage may occur.

NOTE: The upper thrust washers are shown in illustration for location purposes only. Do not install the upper thrust washers until the crankshaft is installed. Refer to the following 2 steps.

Fig 8: Locating Crankshaft Onto Upper Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

Install the crankshaft onto the upper crankshaft main bearings.
Install the lower crankshaft flange bearing onto the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
Install the 20 vertical inner and outer main bearing cap fasteners and the main bearing side bolts finger-tight.
Apply a forward load to the crankshaft, so that the crankshaft thrust face is seated.
Tighten the 10 vertical outer main bearing cap fasteners in 3 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 35 Nm (26 lb-ft).
- Stage 2: Tighten to 50 Nm (26 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
Fig 9: Identifying Vertical Outer Main Bearing Cap Fasteners Tightening Sequence
Courtesy of FORD MOTOR CO.
Tighten the 10 vertical inner main bearing cap fasteners in 3 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 35 Nm (26 lb-ft).
- Stage 2: Tighten to 65 Nm (48 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
Fig 10: Identifying Vertical Inner Main Bearing Cap Fasteners Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the 10 side bolts and tighten them in 3 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 35 Nm (26 lb-ft).
- Stage 3: Tighten an additional 60 degrees.
Fig 11: Identifying Vertical Main Bearing Side Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Check the crankshaft end play clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Assemble the 8 pistons. For additional information, refer to Piston .
Make sure the ring gaps (upper compression ring - A, oil control segment ring - B, expander ring and lower compression ring - C) are correctly spaced around the circumference of the piston.

Fig 12: Identifying Piston Ring Gap Direction
Courtesy of FORD MOTOR CO.

NOTE: Do not allow the connecting rod to come into contact with the piston oil cooler valves during assembly or engine damage may occur.

NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only one connecting rod, rod bearing and piston is shown in illustration.

NOTE: The arrow on the top of the piston faces the front of the engine.

Fig 13: Installing Connecting Rod With Upper Connecting Rod Bearing

Courtesy of FORD MOTOR CO.

Using the Piston Ring Compressor and the Connecting Rod Installer, install the connecting rod with the upper connecting rod bearing in place.
- Lubricate the piston and ring with clean engine oil.
- Lubricate the rod bearings with clean engine oil.

NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

Fig 14: Removing Connecting Rod Installer

Courtesy of FORD MOTOR CO.

Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.

NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

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.

Position the lower bearing and connecting rod, and install the 16 new bolts loosely.
Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

NOTE: Main bearing caps are removed for clarity.

Fig 15: Identifying Main Bearing Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Tighten the 16 bolts in 2 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 43 Nm (32 lb-ft).
- Stage 3: Tighten an additional 135 degrees.
Position the oil pump and install the 2 upper bolts and the lower stud bolts in 5 stages.
- Stage 1: Tighten all fasteners to 2 Nm (18 lb-in).
- Stage 2: Tighten the 2 upper bolts to 10 Nm (89 lb-in).
- Stage 3: Tighten the 2 lower stud bolts to 20 Nm (177 lb-in).
- Stage 4: Tighten the 2 upper bolts an additional 45 degrees.
- Stage 5: Tighten the 2 lower stud bolts an additional 60 degrees.
Fig 16: Locating Oil Pump Upper Bolts And Lower Stud Bolts
Courtesy of FORD MOTOR CO.

NOTE: 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 the O-ring with clean engine oil prior to installation.

Fig 17: Locating Oil Pump Screen And Pickup Tube Bolts

Courtesy of FORD MOTOR CO.

Position the oil pump screen and pickup tube and install the 2 front bolts.
- Tighten to 10 Nm (89 lb-in).
Install the oil pump screen and pickup tube support bracket nut.
- Tighten to 24 Nm (18 lb-ft).
Fig 18: Locating Oil Pump Screen And Pickup Tube Support Bracket Nut
Courtesy of FORD MOTOR CO.
Position the crankshaft keyway at the 11 o'clock position.

NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.

NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry or engine damage may occur.

NOTE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown in illustration, RH similar.

Fig 19: Positioning Cylinder Head Gaskets And Cylinder Heads Over Dowels

Courtesy of FORD MOTOR CO.

Using the Cylinder Head Alignment Pins, position the new cylinder head gaskets and cylinder heads over the dowels and install the 21 cylinder head bolts loosely.
Tighten the 21 bolts in 6 stages, in the sequence shown in illustration.
- Stage 1: Tighten the M12 fasteners to 25 Nm (18 lb-ft).
- Stage 2: Tighten the M12 fasteners to 60 Nm (44 lb-ft).
- Stage 3: Tighten the M12 fasteners an additional 90 degrees.
- Stage 4: Tighten the M12 fasteners an additional 90 degrees.
- Stage 5: Tighten the M8 fastener to 20 Nm (18 lb-ft).
- Stage 6: Tighten the M8 fastener and additional 45 degrees.
Fig 20: Identifying Cylinder Head And Gaskets Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Using a small pick, carefully push the tensioner rack pawl retainer away from the rack pawl and compress the tensioner plunger and rack using a vise.

Fig 21: Pushing Tensioner Rack Pawl Retainer Using Small Pick
Courtesy of FORD MOTOR CO.
Install a small pick into the tensioner to hold the rack pawl and plunger in the seated position for tensioner installation.

Fig 22: Installing Small Pick Into Tensioner
Courtesy of FORD MOTOR CO.
Remove the tensioner from the vise.
If the blue links are not visible, mark 2 links on each end, and use as timing marks.

Fig 23: Locating Timing Chain Colored Links
Courtesy of FORD MOTOR CO.

NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel and above the chain guide pin.

Fig 24: Aligning Timing Mark On Outer Flange Of Camshaft Phaser And Sprocket

Courtesy of FORD MOTOR CO.

Position the upper end of the LH (inner) timing chain on the LH camshaft phaser and sprocket, aligning the timing mark on the outer flange of the camshaft phaser and sprocket with the single blue (marked) link on the chain.
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 blue (marked) link on the chain and install the crankshaft sprocket onto the crankshaft and verify the crankshaft keyway is at the 11 o'clock position

Fig 25: Locating Lower End Of LH (Inner) Timing Chain On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the LH timing chain tensioner arm.

Fig 26: Locating LH Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
Position the LH timing chain tensioner and install the 2 bolts in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 27: Locating LH Timing Chain Tensioner Bolts
Courtesy of FORD MOTOR CO.
Position the LH timing chain guide and install the bolt in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 28: Locating LH Timing Chain Guide And Bolt
Courtesy of FORD MOTOR CO.
Remove the retaining clip from the LH timing chain tensioner.
Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single blue (marked) chain link.

Fig 29: Locating Lower End Of RH (Outer) Timing Chain On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Position the upper end of the RH (outer) timing chain on the RH camshaft phaser and sprocket, aligning the timing mark on the outer flange of the camshaft phaser and sprocket with the single blue (marked) link on the chain.

Fig 30: Aligning Timing Mark On Outer Flange Of Camshaft Phaser And Sprocket
Courtesy of FORD MOTOR CO.
Position the RH timing chain tensioner arm on the dowel pin and the RH timing chain tensioner and install the 2 bolts in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 31: Locating RH Timing Chain Tensioner And Tensioner Arm Bolts
Courtesy of FORD MOTOR CO.
Position the RH timing chain guide and install the bolt in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 32: Locating RH Timing Chain Guide Bolt
Courtesy of FORD MOTOR CO.
Remove the retaining clip from the RH timing chain tensioner.
As a post-check, verify correct alignment of all timing marks.

Fig 33: Locating Timing Marks Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Lubricate the rocker arm shaft-to-valve tip and rocker arm-to-camshaft lobe contact area with clean engine oil prior to installation.
Rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully opened.
Position the LH intake rocker arm shaft assembly and install the bolts finger-tight.
Tighten the 10 LH intake rocker arm shaft assembly bolts in the sequence shown in illustration, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
Fig 34: Identifying LH Intake Rocker Arm Shaft Assembly Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully opened.
Position the LH exhaust rocker arm shaft assembly and install the bolts finger-tight.
Tighten the 10 LH exhaust rocker arm shaft assembly bolts in the sequence shown in illustration, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
Fig 35: Identifying LH Exhaust Rocker Arm Shaft Assembly Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully closed.
Position the RH intake rocker arm shaft assembly and install the bolts finger-tight.
Tighten the 10 RH intake rocker arm shaft assembly bolts in the sequence shown in illustration, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
Fig 36: Identifying RH Intake Rocker Arm Shaft Assembly Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully closed.
Position the RH exhaust rocker arm shaft assembly and install the bolts finger-tight.
Tighten the 10 RH exhaust rocker arm shaft assembly bolts in the sequence shown in illustration, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
Fig 37: Identifying RH Exhaust Rocker Arm Shaft Assembly Bolts Tightening Sequence
Courtesy 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 to remove all traces of old sealant.

NOTE: If the engine front cover is not secured within 5 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Fig 38: Identifying Silicone Gasket And Sealant Applying Dimension On Cylinder Head-To-Cylinder Block And Oil Pan-To-Cylinder Block Surfaces

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown in illustration.

NOTE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully depressed to avoid interference with the VCT valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.

Fig 39: Installing Engine Front Cover With Engine Front Cover Gasket

Courtesy of FORD MOTOR CO.

Install new engine front cover gaskets on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.

Tighten the 20 engine front cover fasteners in the sequence shown in illustration in 3 stages.

Stage 1: Tighten all fasteners to 10 Nm (89 lb-in).

Stage 2: Tighten all fasteners to 20 Nm (177 lb-in).

Stage 3: Tighten all fasteners an additional 45 degrees.

Item	Part Number	Description
1	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
2	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
3	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
4	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
5	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
6	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
7	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
8	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
9	W713462	Stud, Hex Head Pilot, M8 x 33 + M10 x 30
10	W713462	Stud, Hex Head Pilot, M8 x 33 + M10 x 30
11	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
12	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
13	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
14	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
15	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
16	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
17	W713461	Stud, Hex Head Pilot, M8 x 33 + M8 x 27
18	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
19	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
20	W713261	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33

Fig 40: Identifying Engine Front Cover Fasteners Tightening Sequence

Courtesy of FORD MOTOR CO.

NOTE: If the rear crankshaft seal retaining plate is not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure may cause future oil leaks.

Fig 41: Identifying Silicone Gasket And Sealant Applying Area Around Groove Of Crankshaft Rear Seal Retainer Plate Sealing Surface

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant around the groove along the rear of crankshaft rear seal retainer plate sealing surface.
Install the crankshaft rear seal retainer plate and the 8 bolts in the sequence shown in illustration, in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 42: Identifying Crankshaft Rear Seal Retainer Plate Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.

NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Fig 43: Identifying Silicone Gasket And Sealant Applying Dimension

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface and at the engine front cover-to-cylinder block sealing surface.
Position a new gasket and the oil pan and install the 20 bolts.
- Tighten the bolts in the sequence shown in illustration in 3 stages.
  - Stage 1: Tighten to 2 Nm (18 lb-in).
  - Stage 2: Tighten to 10 Nm (89 lb-in).
  - Stage 3: Tighten an additional 45 degrees.
Fig 44: Identifying Oil Pan Gasket Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Lubricate the engine front cover and the new crankshaft seal inner lip with clean engine oil.

Fig 45: Locating Engine Oil Lubrication Area On Engine Front Cover And Crankshaft Seal Inner Lip
Courtesy of FORD MOTOR CO.
Using the Crankshaft Damper and Crankshaft Front Seal Installer and the Front Cover Oil Seal Installer, install the new crankshaft front seal into the engine front cover.

Fig 46: Installing Crankshaft Front Seal Into Engine Front Cover
Courtesy of FORD MOTOR CO.

NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Fig 47: Locating Silicone Gasket And Sealant Applying Area Into Woodruff Key Slot Of Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation.

Fig 48: Locating Engine Oil Lubrication On Crankshaft Pulley Sealing Area
Courtesy of FORD MOTOR CO.
Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

Fig 49: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 2 stages:
- Stage 1: Tighten to 175 Nm (129 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Fig 50: Installing Crankshaft Pulley Bolt And Washer
Courtesy of FORD MOTOR CO.

NOTE: 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.

NOTE: Lubricate the new O-ring seal using clean engine coolant prior to installation.

Fig 51: Locating Coolant Pump Bolts Of Cylinder Block

Courtesy of FORD MOTOR CO.

Using a new O-ring seal, position the coolant pump and install the 4 bolts in 2 stages.
- Stage 1: Tighten to 20 Nm (117 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
Fig 52: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
Install the 2 accessory drive idler pulleys, the coolant pump pulley and the 6 bolts.
- Tighten to 25 Nm (18 lb-ft).
Fig 53: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulleys Bolts
Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the mating surfaces, and install a new gasket.

Fig 54: Locating Oil Filter Adapter Bolts

Courtesy of FORD MOTOR CO.

Using new 3 new O-rings seals, position the oil filter adapter and install the 5 bolts in 2 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Fig 55: Identifying Bead Of Silicone Gasket And Sealant Applying Dimension On Engine Front Cover

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

NOTE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

Fig 56: Identifying RH Valve Cover Fasteners Tightening Sequence

Courtesy of FORD MOTOR CO.

Using a new gasket, position the RH valve cover on the cylinder head and tighten the 10 fasteners in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).

Fig 57: Identifying Silicone Gasket And Sealant Applying Dimension On Engine Front Cover

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

NOTE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

Fig 58: Identifying LH Valve Cover Fasteners Tightening Sequence

Courtesy of FORD MOTOR CO.

Using a new gasket, position the LH valve cover on the cylinder head and tighten the 10 fasteners in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
Install the oil level indicator tube and the bolt.
- Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
- Tighten to 10 Nm (89 lb-in).
Fig 59: Locating Oil Level Indicator Tube And Bolt
Courtesy of FORD MOTOR CO.

NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque or damage to the bolts may occur. Place a visible mark on the engine mount bracket and bracket bolts after the bolts are tightened to 30 Nm (22 lb-ft). Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

Fig 60: Locating RH Engine Support Insulator-To-Cylinder Block Bracket And Bolts

Courtesy of FORD MOTOR CO.

Position the RH engine support insulator bracket and install 4 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 60 degrees.

NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.

Fig 61: Locating LH Support Insulator-To-Cylinder Block Bolts

Courtesy of FORD MOTOR CO.

Position the LH engine support insulator bracket and install 4 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
If not equipped with A/C, position the serpentine belt Idler and bracket assembly and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
Fig 62: Locating Serpentine Belt Idler And Bracket Assembly Bolts
Courtesy of FORD MOTOR CO.

NOTE: LH shown in illustration, RH similar.

Fig 63: Locating Exhaust Manifold Studs

Courtesy of FORD MOTOR CO.

Install 16 new exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).
Using new exhaust manifold nuts, position the LH exhaust manifold and install the 8 nuts in 2 stages in the sequence shown in illustration.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
Fig 64: Identifying Exhaust Manifold Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.
Position the LH exhaust manifold heat shield and install the 2 bolts.
- Tighten to 12 Nm (106 lb-in).
Fig 65: Locating Exhaust Manifold Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Using new exhaust manifold nuts, position the RH exhaust manifold and install the 8 nuts in 2 stages in the sequence shown in illustration.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
Fig 66: Identifying Exhaust Manifold Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.
Position the RH exhaust manifold heat shield and install the 2 bolts.
- Tighten to 12 Nm (106 lb-in).
Fig 67: Locating RH Exhaust Manifold Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Install the 2 Knock Sensor (KS) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Fig 68: Locating RH And LH Knock Sensor Bolts
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Fig 69: Locating LH And RH CMP Sensors Bolts

Courtesy of FORD MOTOR CO.

Install the LH and RH Camshaft Position (CMP) sensors and the 2 bolt.
- Tighten to 10 Nm (89 lb-in).

NOTE: RH shown in illustration, LH similar.

Fig 70: Locating Ignition Wires Of Valve Cover Retainers And Lower Spark Plugs

Courtesy of FORD MOTOR CO.

Connect the 8 ignition wires to the valve cover retainers and the lower spark plugs.
Position the wiring harness onto the engine assembly.
Connect the 3 engine wiring harness position retainers to the RH valve cover.

Fig 71: Locating Engine Wiring Harness Position Retainers
Courtesy of FORD MOTOR CO.
Connect the RH VCT system oil control solenoid electrical connector and the 2 wiring harness retainers.

Fig 72: Locating RH Variable Camshaft Timing System Oil Control Solenoid Electrical Connector And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Position the radio ignition interference capacitor and install the nut.
- Tighten to 25 Nm (18 lb-ft).
Fig 73: Locating Radio Ignition Interference Capacitor Nut
Courtesy of FORD MOTOR CO.
Connect the LH and RH CMP electrical connectors.

Fig 74: Locating LH And RH Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the wiring harness retainer, the KS and Cylinder Head Temperature (CHT) sensor electrical connectors.

Fig 75: Locating Wiring Harness Retainer, Knock Sensor And Cylinder Head Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 3 engine wiring harness position retainers to the LH valve cover.

Fig 76: Locating Engine Wiring Harness Position Retainers Of LH Valve Cover
Courtesy of FORD MOTOR CO.
Connect the LH Variable Camshaft Timing (VCT) system oil control solenoid electrical connector and the 2 wiring harness retainers.

Fig 77: Locating LH Variable Camshaft Timing System Oil Control Solenoid Electrical Connector And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainer.

Fig 78: Locating Engine Oil Pressure Switch Electrical Connector And Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Install the Engine Lifting Bracket and Engine Support Brackets.

Fig 79: Installing Engine Lifting Bracket And Engine Support Brackets
Courtesy of FORD MOTOR CO.
Using a suitable floor crane, remove the engine from the engine stand.

NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.

Fig 80: Installing Crankshaft Rear Seal

Courtesy of FORD MOTOR CO.

Using the Rear Main Seal Installer and Handle, install a new crankshaft rear seal.

NOTE: Inspect the ignition pulse ring for damage. If the ignition pulse ring has been dropped or has any visual damage, it must be discarded.

Fig 81: Locating Inset Holes On Crankshaft Ignition Pulse Ring And Crankshaft Flange

Courtesy of FORD MOTOR CO.

With the inset hole on the crankshaft ignition pulse ring aligned with the inset hole on the crankshaft flange, install the crankshaft ignition pulse ring.

NOTE: The Crankshaft Position (CKP) sensor must be positioned into the fitting on the crankshaft rear seal retainer plate and be flush against the boss on the engine block before the bolt is installed. If the CKP sensor is installed incorrectly, the CKP sensor can be damaged.

Fig 82: Locating Electrical Connector And Bolt Of Crankshaft Position Sensor

Courtesy of FORD MOTOR CO.

Position the Crankshaft Position (CKP) sensor, install the bolt and connect the electrical connector.
- Tighten to 10 Nm (89 lb-in).
Remove the engine rear cover plate.

Fig 83: Locating Spacer Plate
Courtesy of FORD MOTOR CO.

NOTE: Flexplate shown in illustration, flywheel similar.

Fig 84: Locating Offset Holes On Crankshaft Ignition Pulse Ring And Flexplate

Courtesy of FORD MOTOR CO.

With the offset hole on the crankshaft ignition pulse ring aligned with the offset hole on the flexplate, position the flexplate and install 8 new bolts finger-tight.

NOTE: Flexplate shown in illustration, flywheel similar.

Fig 85: Identifying Flexplate Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Tighten the 8 new bolts in 6 stages.
- Stage 1: Tighten fasteners 1 through 4 in sequence to 20 Nm (177 lb-in).
- Stage 2: Tighten fasteners 1 through 4 in sequence to 35 Nm (26 lb-ft).
- Stage 3: Tighten fasteners 1 through 4 in sequence an additional 60 degrees.
- Stage 4: Tighten fasteners 5 through 8 in sequence to 20 Nm (177 lb-in).
- Stage 5: Tighten fasteners 5 through 8 in sequence to 35 Nm (26 lb-ft).
- Stage 6: Tighten fasteners 5 through 8 in sequence an additional 60 degrees.

NOTE: Flexplate shown in illustration, flywheel similar.

Rotate the crankshaft clockwise until the 2 flexplate slotted holes are at the 6 o'clock position as shown in illustration prior to engine installation.

Fig 86: Locating Flexplate Slotted Holes

Courtesy of FORD MOTOR CO.