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WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Record the main bearing code found on the front of the engine block.
    Fig 1: Identifying Main Bearing Code Found On Front Of Engine Block
    G04583819Courtesy of FORD MOTOR CO.
  2. Record the main bearing code found on the back of the crankshaft.
    Fig 2: Identifying Main Bearing Code - Found On Back Of Crankshaft
    G03886015Courtesy of FORD MOTOR CO.
  3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
    • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
    • Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the number one crankshaft main bearing.
    • As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is a "2."
    • Repeat this process for the remaining 4 main bearings.
    Fig 3: Bearing Select Fit Chart (Standard Bearings)
    G03886016Courtesy of FORD MOTOR CO.
  4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
    Fig 4: Bearing Select Fit Chart (Oversize Bearings)
    G04583822Courtesy of FORD MOTOR CO.
    5. 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.
    6. NOTE: The upper thrust washers are shown for location purposes only. Do not install the upper thrust washers until the crankshaft is installed. Refer to the following 2 steps.
    Fig 5: Installing Crankshaft Onto Upper Crankshaft Main Bearings
    GF0002802Courtesy of FORD MOTOR CO.
  6. Install the crankshaft onto the upper crankshaft main bearings.
    7. 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
    GF0000612Courtesy 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.
    8. 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
    GF0002803Courtesy 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.
    9. 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
    GF0002804Courtesy 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, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
  11. Install the dowel pins so the flat sides face the crankshaft.
    Fig 9: Installing Dowel Pins
    GF0002805Courtesy 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 10: Tightening Main Bearing Cap Fasteners In Sequence
    GF0002806Courtesy 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 11: Tightening Side Bolts In Sequence
    GF0002807Courtesy of FORD MOTOR CO.
  14. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  15. Assemble the 8 pistons. For additional information, refer to Piston  in this article.
  16. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
    Fig 12: Identifying Piston Ring Gap Positioning
    G03920387Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only 1 connecting rod, rod bearing and piston is shown.
    Fig 13: Using Special Tools To Install Piston And Connecting Rod Assembly
    G03920388Courtesy of FORD MOTOR CO.
  17. Use the special tools to 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.
    18. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 14: Identifying Special Tool
    G03920389Courtesy of FORD MOTOR CO.
  18. Once the connecting rod is seated on the crankshaft journal, remove the special tools.
    19. 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.
  19. Position the lower bearing and connecting rod, and install the new bolts loosely.
    20. NOTE: Main bearing caps are removed for clarity.
    Fig 15: Identifying Tighten Sequence Of Connecting Rod Bearing Caps
    G03920390Courtesy of FORD MOTOR CO.
  20. Tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 43 N.m (32 lb-ft).
    • Stage 2: Tighten an additional 105 degrees.
  21. Position the oil pump and install the bolts.
    • Tighten to 10 N.m (89 lb-in).
    Fig 16: Locating Oil Pump Bolts
    G04638972Courtesy of FORD MOTOR CO.
  22. Install the oil pump screen and pickup tube spacer.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 17: Installing Oil Pump Screen And Pickup Tube Spacer
    GF0002808Courtesy of FORD MOTOR CO.
    23. 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 the O-ring with clean engine oil prior to installation.
    Fig 18: Positioning Oil Pump Screen, Pickup Tube And Installing Bolts
    GF0002809Courtesy of FORD MOTOR CO.
  23. Position the oil pump screen and pickup tube and install the bolts.
    • Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 N.m (89 lb-in).
    • Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 N.m (18 lb-ft).
  24. Position the crankshaft with the special tool, then remove the tool.
    Fig 19: Positioning Crankshaft With Special Tool
    G03919963Courtesy of FORD MOTOR CO.
    25. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    NOTE: Do not turn the crankshaft until instructed to do so.
    NOTE: LH shown, RH similar.
    Fig 20: Locating Cylinder Head And Gaskets Using Special Tool
    G03920395Courtesy of FORD MOTOR CO.
  25. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
  26. Tighten the bolts in 3 stages, in the sequence shown.

    RH shown, LH 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 21: Tightening Bolts In Sequence
    GF0002810Courtesy of FORD MOTOR CO.
  27. Remove the special tool from the LH cylinder head.
    Fig 22: Identifying Special Tool Onto Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  28. Remove the special tool from the RH cylinder head.
    Fig 23: Identifying Special Tool On Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
  29. Install the hydraulic lash adjusters into the RH and LH cylinder heads.
    • Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
    Fig 24: Identifying Hydraulic Lash Adjusters
    G03920399Courtesy of FORD MOTOR CO.
  30. Install the LH and RH camshafts.
    • Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
    31. NOTE: LH shown, RH similar.
    Fig 25: Identifying Camshaft Bearing Caps Loosening/Tightening Sequence
    G03963330Courtesy of FORD MOTOR CO.
  31. Install the LH and RH camshaft bearing caps in their original locations.
    • Lubricate the camshaft bearing caps with clean engine oil.
    • Position the front camshaft bearing cap.
    • Position the remaining camshaft bearing caps.
    • Install the bolts loosely.
    • Tighten to 10 N.m (89 lb-in) in the sequence shown.
    32. CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    NOTE: LH shown, RH similar.
    Fig 26: Identifying Camshaft Phaser And Sprocket Assembly Bolt
    G03919961Courtesy of FORD MOTOR CO.
  32. Install the VCT phaser sprockets and new VCT phaser bolts finger tight.
    33. CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
    NOTE: LH shown, RH similar.
  33. Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    34. Fig 27: Identifying Special Sprocket Phase Tool
    G03919955Courtesy of FORD MOTOR CO.
    CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Failure to follow these instructions may result in engine damage.
  34. Compress the tensioner plunger, using a vise.
    35. Fig 28: Compressing Tensioner Plunger
    G03885344Courtesy of FORD MOTOR CO.
  35. Install a retaining clip on the tensioner to hold the plunger in during installation.
    36. Fig 29: Identifying Retaining Clip on Tensioner
    G03881580Courtesy of FORD MOTOR CO.
  36. Remove the tensioner from the vise.
  37. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
    38. Fig 30: Locating Timing Chain Marks
    G03885317Courtesy of FORD MOTOR CO.
  38. Install the crankshaft sprocket, making sure the flange faces forward.
    39. Fig 31: Identifying Crankshaft Sprocket
    G03919967Courtesy of FORD MOTOR CO.
  39. Install the 4 bolts and the LH and RH timing chain guides.
    • Tighten to 10 N.m (89 lb-in).
    40. Fig 32: Identifying Timing Chain Guides
    G03933858Courtesy of FORD MOTOR CO.
  40. 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.
    41. Fig 33: Aligning Crankshaft Sprocket Timing Mark And LH Timing Chain Link
    G03919969Courtesy of FORD MOTOR CO.
    NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
  41. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.
    42. Fig 34: Identifying Copper Links Of Timing Chain On VCT Phaser Sprocket
    G03919970Courtesy of FORD MOTOR CO.
    NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
  42. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
    43. Fig 35: Identifying LH Timing Chain Tensioner & Tensioner Arm
    G03919950Courtesy of FORD MOTOR CO.
  43. Remove the retaining clip from the LH timing chain tensioner.
    44. Fig 36: Identifying Retaining Clip And Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  44. 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.
    45. Fig 37: Aligning Crankshaft Sprocket Timing Mark And RH Timing Chain Link
    G03919973Courtesy of FORD MOTOR CO.
    NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
    NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.
  45. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.
    46. Fig 38: Positioning RH Timing Chain On Camshaft Sprocket
    GF0002756Courtesy of FORD MOTOR CO.
  46. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
    47. Fig 39: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
    G03919951Courtesy of FORD MOTOR CO.
  47. Remove the retaining clip from the RH timing chain tensioner.
    48. Fig 40: Identifying Retaining Clip And Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  48. As a post-check, verify correct alignment of all timing marks.
    49. Fig 41: Locating Timing Marks
    G06126287Courtesy of FORD MOTOR CO.
  49. Install the crankshaft sensor ring on the crankshaft.
    50. Fig 42: Locating Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage.
  50. Using the special tool, install all of the camshaft roller followers.
    • Lubricate the camshaft roller followers with clean engine oil prior to installation.
    51. Fig 43: Compressing Spring Using Special Tool (303-1039)
    G03919948Courtesy 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.
    NOTE: If the engine front cover is not secured within 4 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
  51. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
    52. Fig 44: Applying Bead Of Silicone Gasket And Sealant
    GF0002811Courtesy of FORD MOTOR CO.
  52. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
    Fig 45: Installing Engine Front Cover Gasket
    GF0000367Courtesy of FORD MOTOR CO.
  53. Tighten the engine front cover fasteners in the sequence shown in 2 stages.

    Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

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

    Fig 46: Tightening Engine Front Cover In Sequence
    GF0002754Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    11 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    15 W706605 Bolt, Hex Head Pilot, M8 x 1.25 x 56
    54. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
    Fig 47: Locating Bolt And LH CMP Sensor
    G03919989Courtesy of FORD MOTOR CO.
  54. Install the LH camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
    55. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
    Fig 48: Locating Camshaft (CMP) Sensor Bolt
    G03920013Courtesy of FORD MOTOR CO.
  55. Install the RH CMP sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
    56. 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 49: Identifying Coolant Pump
    G03885759Courtesy of FORD MOTOR CO.
  56. Position the coolant pump and install the bolts loosely.
    • Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
  57. Tighten the 4 coolant pump bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 50: Tightening Coolant Pump Bolts
    GF0000354Courtesy of FORD MOTOR CO.
  58. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
    Fig 51: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  59. Using the special tools, install a new crankshaft seal into the engine front cover.
    Fig 52: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    60. NOTE: If not secured within 4 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. 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 53: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  60. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  61. Use the special tool to install the crankshaft pulley.
    Fig 54: Using Special Tool To Install Crankshaft Pulley
    G03920552Courtesy of FORD MOTOR CO.
  62. Tighten the new crankshaft pulley bolt in 4 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 55: Tightening Crankshaft Pulley Bolt
    GF0002723Courtesy of FORD MOTOR CO.
  63. Position the crankshaft position (CKP) sensor and the bolt.
    • Install the new O-ring seal and lubricate the new O-ring seal with clean engine oil prior to installation.
    • Tighten to 10 N.m (89 lb-in).
    Fig 56: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
  64. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 57: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
  65. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 58: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts
    G03933688Courtesy of FORD MOTOR CO.
    66. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: Clean and inspect the mating surfaces, and install new gaskets.
    Fig 59: Installing Oil Filter Adapter
    GF0002693Courtesy of FORD MOTOR CO.
  66. Position the oil filter adapter and install the 4 bolts.
    • Tighten to 25 N.m (18 lb-ft).
  67. Install 8 new LH exhaust manifold-to-cylinder head studs.
    • Tighten to 12 Nm (9 lb-ft).
    Fig 60: Locating LH Exhaust Manifold-To-Cylinder Head Studs
    GF0002793Courtesy of FORD MOTOR CO.
  68. Position a new gasket, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 61: Identifying Tightening Sequence Of LH Exhaust Manifold Nuts
    GF0002767Courtesy of FORD MOTOR CO.
    69. CAUTION: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
    Fig 62: Installing LH Engine Support Insulator Bolts
    GF0002692Courtesy of FORD MOTOR CO.
  69. Install the LH engine support insulator and the 3 bolts.
    • Apply threadlock to the bolt threads prior to installation.
    • Tighten to 63 N.m (46 lb-ft).
  70. Install 8 new RH exhaust manifold-to-cylinder head studs.
    • Tighten to 12 Nm (9 lb-ft).
    Fig 63: Locating RH Exhaust Manifold-To-Cylinder Head Studs
    GF0002795Courtesy of FORD MOTOR CO.
  71. Position a new gasket, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 64: Identifying Tightening Sequence Of RH Exhaust Manifold Bolts
    GF0002770Courtesy of FORD MOTOR CO.
    72. CAUTION: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
    Fig 65: Identifying RH Engine Support Insulator Bolts
    G03933620Courtesy of FORD MOTOR CO.
  72. Install the RH engine support insulator and the 3 bolts.
    • Apply threadlock to the bolt threads prior to installation.
    • Tighten to 63 N.m (46 lb-ft).
    73. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  73. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    74. NOTE: If not secured within 4 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. 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 66: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
    G03919863Courtesy of FORD MOTOR CO.
  74. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.


    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  1. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    2. NOTE: If not secured within 4 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. 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 1: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
    G03919870Courtesy of FORD MOTOR CO.
  2. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.


  1. 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 N.m (89 lb-in).
    Fig 1: Installing Oil Level Indicator Tube
    GF0002790Courtesy of FORD MOTOR CO.
    2. NOTE: Do not reuse the O-ring seals.
    NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation.
    Fig 2: Sliding Coolant Tube Forward With O-Ring Seals Into Cylinder Block
    GF0000368Courtesy of FORD MOTOR CO.
  2. Slide the coolant tube forward with the new O-ring seals into the cylinder block.
  3. Install the coolant tube stud bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 3: Identifying Coolant Tube Stud Bolt
    G03920263Courtesy of FORD MOTOR CO.
  4. Install the 2 knock sensors (KS) and the bolts.
    • Tighten to 20 N.m (15 lb-ft).
    Fig 4: Identifying Knock Sensors (KS)
    G03920293Courtesy of FORD MOTOR CO.
  5. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
  6. Connect the CKP sensor electrical connector.
    Fig 5: Connecting CKP Sensor Electrical Connector
    GF0002667Courtesy of FORD MOTOR CO.
  7. Connect the 4 LH ignition coil electrical connectors.
    Fig 6: Connecting LH Ignition Coil Electrical Connectors
    GF0002730Courtesy of FORD MOTOR CO.
  8. Install the LH radio ignition interference capacitor and the stud bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 7: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
    G03920225Courtesy of FORD MOTOR CO.
  9. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 8: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  10. Connect the 4 RH ignition coil electrical connectors.
    Fig 9: Locating Ignition Coil Electrical Connectors
    G03920223Courtesy of FORD MOTOR CO.
  11. Connect the electrical connector retainer to the coolant tube.
    Fig 10: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  12. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 11: Locating Engine Wiring Harness Retainers At RH Valve Cover
    G03920221Courtesy of FORD MOTOR CO.
  13. Connect the RH VCT solenoid electrical connector.
    Fig 12: Locating Camshaft Timing (VCT) Solenoid Electrical Connectors
    G03920220Courtesy of FORD MOTOR CO.
  14. Install the RH radio ignition interference capacitor and the stud bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 13: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
    G03920219Courtesy of FORD MOTOR CO.
  15. Connect the RH CMP sensor electrical connector.
    Fig 14: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  16. Install the special tool.
    Fig 15: Identifying Special Tool
    G03920205Courtesy of FORD MOTOR CO.
  17. Using a suitable floor crane, remove the engine from the engine stand.
    18. 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.
  18. Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    19. NOTE: If not secured within 4 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. 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 16: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
    GF0002781Courtesy of FORD MOTOR CO.
  19. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
  20. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
    Fig 17: Locating Crankshaft Rear Seal Retainer Plate Bolts
    GF0000369Courtesy of FORD MOTOR CO.
  21. Tighten the bolts in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
    Fig 18: Tightening Bolts In Sequence
    GF0002812Courtesy of FORD MOTOR CO.
    22. 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.
  22. 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.
    23. NOTE: If not secured within 4 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. 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 19: Applying Silicone Gasket And Sealant
    GF0000322Courtesy of FORD MOTOR CO.
  23. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
    24. NOTE: If not secured within 4 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. 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 20: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Mating Surface
    G03920465Courtesy of FORD MOTOR CO.
  24. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
  25. Install the oil pan gasket and the oil pan and loosely install the bolts.
    Fig 21: Positioning New Oil Pan Gasket And Oil Pan
    GF0000323Courtesy of FORD MOTOR CO.
  26. Tighten the bolts in 3 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 60 degrees.
    Fig 22: Identifying Oil Pan Bolt Tightening Sequence
    G03920110Courtesy of FORD MOTOR CO.
    27. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
    Fig 23: Using Special Tools To Install New Crankshaft Rear Seal
    G04583928Courtesy of FORD MOTOR CO.
  27. Using the special tools, install a new crankshaft rear seal.
  28. Using the special tools, install a new crankshaft rear oil slinger.
    Fig 24: Installing Crankshaft Rear Oil Slinger Using Special Tools
    G03920154Courtesy of FORD MOTOR CO.
  29. Install the flexplate and the 8 bolts in the sequence shown.
    • Tighten to 80 N.m (59 lb-ft).
    Fig 25: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts
    G03920141Courtesy of FORD MOTOR CO.
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