Section 788 (Engine - 5.4L (3V) - F250 & F350): Assembly: Engine

WARNING: This page is about a different car, the 2007 Ford Pickup and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools

Illustration	Tool Name	Tool Number
	Remover/Installer, Cylinder Head	303-572 (T97T-6000-A)
	Installer, Connecting Rod	303-442 (T93P-6136-A)
	Compressor, Valve Spring	303-1039
	Installer, Crankshaft Vibration Damper	303-102 (T74P-6316-B)
	Installer, Crankshaft Front Seal	303-635
	Installer, Front Cover Seal	303-335 (T88T-6701-A)
	Compressor, Piston Ring	303-D032 (D81L-6002-C) or equivalent
	Installer, Crankshaft Rear Seal	303-518 (T95P-6701-DH)
	Installer, Crankshaft Oil Slinger	303-517 (T95P-6701-CH)
	Installer, Crankshaft Rear Seal	303-516 (T95P-6701-EH)
	Alignment Pins, Cylinder Head	303-1040 (SR-015486)
	Modular Engine Lift Bracket	303-F047 (014-00073) or equivalent
	Locking Tool, Camshaft Phaser Sprocket	303-1046
	Holding Tool, Crankshaft	303-448 (T93P-6303-A)

Material

Item	Specification
Motorcraft Metal Surface Prep ZC-31	-
Silicone Gasket Remover ZC-30	-
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent	WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)	WSS-M97B51-A1
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA	-

Fig 1: Identifying Engine - Upper End

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	12B637	Engine wiring harness
2	6A505	Valve cover - LH
3	6750	Oil level indicator
4	N605892	Oil level indicator tube bolt
5	6K873	Oil level indicator tube
6	N807834	Camshaft bearing cap bolt (10 required)
7	6B280	Camshaft bearing cap (4 required)
8	6C255	Camshaft - LH
9	6529	Roller follower (24 required)
10	6518	Valve spring retainer key (48 required)
11	6514	Valve spring retainer (24 required)
12	6513	Valve spring (24 required)
13	6A517	Valve stem seal (24 required)
14	6C501	Hydraulic lash adjuster (24 required)
15	6279	Camshaft phaser sprocket bolt - LH
16	6C524	Camshaft phaser sprocket - LH
17	6B284	Camshaft bearing cap
18	12405	Spark plug (4 required)
19	12A366	Ignition coil (4 required)
20	6065	Cylinder head bolt (20 required)
21	W707747	Exhaust manifold stud (8 required)
22	9Y431	Exhaust manifold gaskets (2 required)
23	9431	Exhaust manifold - LH
24	W701706	Exhaust manifold nut (8 required)
25	6507	Intake valve (16 required)
26	6505	Exhaust valve (8 required)
27	6083	Cylinder head gasket - LH
28	W701520	Variable camshaft timing (VCT) oil control solenoid assembly bolt (2 required)
29	6C261	VCT oil control solenoid assembly
30	6050	Cylinder head - LH
31	14B102	Cylinder head temperature (CHT) sensor jumper harness
32	W701571	Heater outlet tube stud bolt
33	18663	Heater outlet tube
34	6051	Cylinder head gasket - RH
35	6049	Cylinder head - RH
36	9Y431	Exhaust manifold gaskets (2 required)
37	9430	Exhaust manifold - RH
38	W701706	Exhaust manifold nut (8 required)
39	W707747	Exhaust manifold stud (8 required)
40	6C260	VCT oil control solenoid assembly
41	W701520	VCT oil control solenoid assembly bolt (2 required)
42	6279	Camshaft phaser sprocket bolt - RH
43	6C524	Camshaft phaser sprocket - RH
44	6B284	Camshaft bearing cap
45	N807834	Camshaft bearing cap bolt (10 required)
46	6B280	Camshaft bearing cap (4 required)
47	6251	Camshaft - RH
48	12405	Spark plug (4 required)
49	12A366	Ignition coil (4 required)
50	W706175	Ignition coil bolt (8 required)
51	6582	Valve cover - RH
52	6765	Oil fill adapter
53	6766	Oil fill adapter cap
54	6758	Crankcase ventilation tube
55	W503282	Coolant crossover tube bolt (3 required)
56	W503279	Thermostat housing bolt (2 required)
57	8594	Thermostat housing
58	N806807	Thermostat O-ring seal
59	8575	Thermostat
60	8C369	Coolant crossover tube
61	6N041	Intake manifold dust cover
62	9A474	Intake manifold vacuum harness
63	9S440	Intake manifold vacuum harness support bracket
64	N811050	Intake manifold vacuum harness support bracket bolt
65	W709775	Intake manifold bolt (10 required)
66	9Y451	Intake manifold assembly
67	6K817	Positive crankcase ventilation (PCV) tube
68	W500204	PCV heater element assembly bolt (2 required)
69	9F624	PCV heater element assembly

Fig 2: Identifying Engine - Front end

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6306	Crankshaft sprocket
2	6B274	Timing chain guide - LH
3	N606527	Timing chain guide lower bolt - LH
4	6268	Timing Chain - LH
5	6K255	Tensioner arm - RH
6	12A227	Ignition pulse wheel
7	W706447	Power steering pump bolt (2 required)
8	3A696	Power steering pump assembly
9	N808529	Engine front cover stud bolt (2 required)
10	N806177	Engine front cover bolt (10 required)
11	6C315	Crankshaft position (CKP) sensor
12	N806155	CKP sensor bolt
13	6700	Crankshaft front seal
14	6316	Crankshaft pulley
15	N806165	Crankshaft pulley washer
16	W701512	Crankshaft pulley bolt
17	8A528	Coolant pump pulley
18	N806282	Coolant pump pulley bolt (4 required)
19	N806177	Coolant pump bolt (4 required)
20	8501	Coolant pump
21	N808102	Accessory drive belt idler pulley bolt
22	12A216	Accessory drive belt idler pulley
23	N806155	Camshaft position (CMP) sensor bolt (2 required)
24	6B288	CMP sensor (2 required)
25	W709573	Engine front cover stud bolt (3 required)
26	N804758	Radio ignition interference capacitor nuts (2 required)
27	18801	Radio ignition interference capacitors (2 required)
28	6C086	Engine front cover
29	N606543	Timing chain tensioner bolt - RH (2 required)
30	6L266	Timing chain tensioner - RH
31	W503282	Timing chain guide bolt - RH (2 required)
32	6268	Timing chain - RH
33	6M256	Timing chain guide - RH
34	N606543	Timing chain tensioner bolt - LH (2 required)
35	6M269	Timing chain tensioner - LH
36	6M274	Tensioner arm - LH
37	N605892	Timing chain guide upper bolt - LH

Fig 3: Identifying Engine - Lower end

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6010	Cylinder block
2	W500225	Knock sensor (KS) bolt (2 required)
3	12A699	KS (2 required)
4	6211	Upper connecting rod bearing (8 required)
5	6135	Piston pin (8 required)
6	6159	Outer oil control ring (8 required)
7	6161	Inner oil control ring (8 required)
8	6150	Upper compression ring (8 required)
9	6152	Lower compression ring (8 required)
10	6159	Outer oil control ring (8 required)
11	6140	Piston pin retainer (16 required)
12	6110	Piston (8 required)
13	6200	Connecting rod assembly (8 required)
14	6K318	Crankshaft rear seal retainer plate
15	6375	Flexplate
16	N806168	Flexplate bolt (8 required)
17	N806168	Flywheel bolt (8 required)
18	6375	Flywheel
19	N806168	Pilot bearing
20	6701	Crankshaft oil slinger
21	6310	Crankshaft rear seal
22	N806155	Crankshaft rear seal retainer plate bolt (6 required)
23	6714	Oil filter
24	6A642	Oil cooler
25	N620482	Oil filter adapter nut
26	6881	Oil filter adapter
27	W704787	Oil filter adapter stud
28	9278	Engine oil pressure (EOP) switch
29	N620482	Oil filter adapter bolt (4 required)
30	6A636	Oil filter adapter gasket
31	W701605	Oil pan bolt (16 required)
32	6675	Oil pan
33	12A648	Engine oil temperature (EOT) sensor
34	6710	Oil pan gasket
35	N605904	Oil pump screen and pickup tube bolt
36	N806155	Oil pump screen and pickup tube bolt (2 required)
37	6622	Oil pump screen and pickup tube
38	N806180	Oil pump screen and pickup tube spacer
39	6345	Crankshaft main bearing cap bolt (9 required)
40	6C357	Crankshaft main bearing cap stud
41	6A346	Crankshaft main bearing dowel (10 required)
42	6325	Crankshaft main bearing cap (5 required)
43	6K302	Crankshaft thrust washer - lower
44	6A338	Crankshaft bearing - lower (5 required)
45	6303	Crankshaft
46	N806201	Crankshaft key
47	6333	Crankshaft bearing - upper (4 required)
48	6A341	Crankshaft thrust washer - upper (2 required)
49	6333	Crankshaft bearing - upper
50	6210	Connecting rod cap (8 required)
51	6211	Connecting rod bearing (8 required)
52	6621	Oil pump
53	N806183	Oil pump bolt (3 required)

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

Fig 4: Identifying Main Bearing Code Found On Front Of Engine Block
Courtesy of FORD MOTOR CO.
Record the main bearing code found on the back of the crankshaft.

Fig 5: Identifying Main Bearing Code - Found 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 number 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 6: 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.

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: Bearing Select Fit Chart (Oversize Bearings)

Courtesy of FORD MOTOR CO.

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 2 steps.

Fig 8: Installing Crankshaft Onto Upper Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

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 9: Installing Rear Crankshaft Upper Thrust Washer

Courtesy of FORD MOTOR CO.

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 10: Installing Front Crankshaft Upper Thrust Washer

Courtesy of FORD MOTOR CO.

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 11: Installing Lower Crankshaft Thrust Washer

Courtesy of FORD MOTOR CO.

Install the lower crankshaft thrust washer to the back side of 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 dowel pins so the flat sides face the crankshaft.

Fig 12: Installing Dowel Pins
Courtesy of FORD MOTOR CO.
Install the vertical main bearing cap fasteners and tighten in 2 stages, in the sequence shown.
- Stage 1: Tighten to 40 N.m (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Fig 13: Identifying Tighten Sequence Of Vertical Main Bearing Cap Fasteners
Courtesy of FORD MOTOR CO.
Install the side bolts and tighten them in 2 stages, in the sequence shown.
- Stage 1: Tighten to 30 N.m (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Fig 14: Tightening Side Bolts In Sequence
Courtesy of FORD MOTOR CO.
Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
Assemble the 8 pistons. For additional information, refer to Piston in this article.
Make sure the ring gaps (oil spacer - A, oil ring - B, compression ring - C) are correctly spaced around the circumference of the piston.

Fig 15: Identifying Piston Ring Gap Positioning
Courtesy of FORD MOTOR CO.

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 one connecting rod, rod bearing and piston is shown.

Fig 16: Using Special Tools To Install Piston And Connecting Rod Assembly

Courtesy of FORD MOTOR CO.

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.

CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Fig 17: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Once the connecting rod is seated on the crankshaft journal, remove the special tool.

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.

Position the lower bearing and connecting rod, and install the new bolts loosely.

NOTE: Main bearing caps are removed for clarity.

Fig 18: Identifying Tighten Sequence Of Connecting Rod Bearing Caps

Courtesy of FORD MOTOR CO.

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.
Position the oil pump and install the bolts.
- Tighten to 10 N.m (89 lb-in).
Fig 19: Locating Oil Pump Bolts
Courtesy of FORD MOTOR CO.
Install the oil pump screen and pickup tube spacer.
- Tighten to 25 N.m (18 lb-ft).
Fig 20: Installing Oil Pump Screen And 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 the O-ring with clean engine oil prior to installation.

Fig 21: Positioning Oil Pump Screen, Pickup Tube And Installing Bolts

Courtesy of FORD MOTOR CO.

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).
Position the crankshaft with the special tool, then remove the tool.

Fig 22: Positioning Crankshaft With Special Tool
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.

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 23: Locating Cylinder Head And Gaskets Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.

NOTE: Tighten the bolts in 3 stages, in the sequence shown.

NOTE: RH shown, LH similar.

Fig 24: Identifying Cylinder Head Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

- Stage 1: Tighten to 40 N.m (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.
Remove the special tool from the LH cylinder head.

Fig 25: Identifying Special Tool Onto Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the special tool from the RH cylinder head.

Fig 26: Identifying Special Tool On Cylinder Head
Courtesy of FORD MOTOR CO.
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 27: Identifying Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.
Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

NOTE: LH shown, RH similar.

Fig 28: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequence

Courtesy of FORD MOTOR CO.

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.

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 29: Identifying Camshaft Phaser And Sprocket Assembly Bolt

Courtesy of FORD MOTOR CO.

Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight.

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.

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.

Fig 30: Identifying Special Sprocket Phase Tool

Courtesy 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.

Compress the tensioner plunger, using a vise.

Fig 31: Compressing Tensioner Plunger

Courtesy of FORD MOTOR CO.

Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 32: Identifying Retaining Clip on Tensioner

Courtesy of FORD MOTOR CO.

Remove the tensioner from the vise.
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.

Fig 33: Locating Timing Chain Marks

Courtesy of FORD MOTOR CO.

Install the crankshaft sprocket, making sure the flange faces forward.

Fig 34: Identifying Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Install the 4 bolts and the LH and RH timing chain guides.
- Tighten to 10 N.m (89 lb-in).

Fig 35: Identifying Timing Chain Guides

Courtesy of FORD MOTOR CO.

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 36: Aligning Crankshaft Sprocket Timing Mark And LH Timing Chain Link

Courtesy of FORD MOTOR CO.

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

Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.

Fig 37: Identifying Copper Links Of Timing Chain On VCT Phaser Sprocket

Courtesy of FORD MOTOR CO.

NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

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).

Fig 38: Identifying LH Timing Chain Tensioner & Tensioner Arm

Courtesy of FORD MOTOR CO.

Remove the retaining clip from the LH timing chain tensioner.

Fig 39: Identifying Retaining Clip And Timing Chain Tensioner

Courtesy of FORD MOTOR CO.

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 40: Aligning Crankshaft Sprocket Timing Mark And RH Timing Chain Link

Courtesy 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.

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.

Fig 41: Positioning RH Timing Chain On Camshaft Sprocket

Courtesy of FORD MOTOR CO.

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).

Fig 42: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts

Courtesy of FORD MOTOR CO.

Remove the retaining clip from the RH timing chain tensioner.

Fig 43: Identifying Retaining Clip And Timing Chain Tensioner

Courtesy of FORD MOTOR CO.

As a post-check, verify correct alignment of all timing marks.

Fig 44: Locating Timing Marks

Courtesy of FORD MOTOR CO.

Install the crankshaft sensor ring on the crankshaft.

Fig 45: Locating Crankshaft Sensor Ring At Crankshaft

Courtesy 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.

Using the special tool, install all of the camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.

Fig 46: Compressing Spring Using Special Tool (303-1039)

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.

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.

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

Fig 47: Applying Bead Of Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

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 48: Installing Engine Front Cover Gasket
Courtesy of FORD MOTOR CO.

Tighten the engine front cover fasteners in sequence 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 49: Tightening Engine Front Cover Fasteners In Sequence

Courtesy 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	Bolts, 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

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

Fig 50: Locating Bolt And LH CMP Sensor

Courtesy of FORD MOTOR CO.

Install the LH camshaft position (CMP) sensor and the bolt.
- Tighten to 10 N.m (89 lb-in).

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

Fig 51: Locating Camshaft (CMP) Sensor Bolt

Courtesy of FORD MOTOR CO.

Install the RH CMP sensor and the bolt.
- Tighten to 10 N.m (89 lb-in).

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 52: Identifying Coolant Pump

Courtesy of FORD MOTOR CO.

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.
Tighten the 4 coolant pump bolts.
- Tighten to 25 N.m (18 lb-ft).
Fig 53: Identifying Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 54: Locating Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install a new crankshaft front seal into the engine front cover.

Fig 55: Installing Crankshaft Front Seal Using Special Tools
Courtesy of FORD MOTOR CO.

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 56: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
Use the special tool to install the crankshaft pulley.

Fig 57: Using Special Tool To Install Crankshaft Pulley
Courtesy of FORD MOTOR CO.
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 58: Tightening Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Position the crankshaft position (CKP) sensor and the bolt.
- Tighten to 10 N.m (89 lb-in).
Fig 59: Locating Crankshaft Position (CKP) Sensor Bolt
Courtesy of FORD MOTOR CO.
Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 N.m (18 lb-ft).
Fig 60: Identifying Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 N.m (18 lb-ft).
Fig 61: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt
Courtesy of FORD MOTOR CO.

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

Fig 62: Positioning Oil Filter Adapter Bolts And Nut

Courtesy of FORD MOTOR CO.

Position the oil filter adapter and install the 4 bolts and the nut.
- Tighten to 25 N.m (18 lb-ft).

NOTE: LH shown, RH similar.

Fig 63: Locating LH Exhaust Manifold-To-Cylinder Head Studs

Courtesy of FORD MOTOR CO.

Install 16 new exhaust manifold studs.
- Tighten to 12 Nm (9 lb-ft).
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 64: Identifying Tightening Sequence Of LH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Install the LH engine support insulator and the 3 bolts.
- Tighten to 63 N.m (46 lb-ft).
Fig 65: Locating LH Engine Support Insulator Bolts
Courtesy of FORD MOTOR CO.
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 66: Identifying Tightening Sequence Of RH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Install the RH engine support insulator bracket and the 4 bolts.
- Tighten to 63 N.m (46 lb-ft).
Fig 67: Identifying RH Engine Support Insulator Bracket Bolts
Courtesy of FORD MOTOR CO.
Install the RH engine support insulator and the 4 bolts.
- Tighten to 63 N.m (46 lb-ft).
Fig 68: Locating RH Engine Support Insulator Bolts
Courtesy of FORD MOTOR CO.

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.

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

Fig 69: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head

Courtesy of FORD MOTOR CO.

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

CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.

Fig 70: Identifying Tightening Sequence Of Valve Cover Bolts

Courtesy of FORD MOTOR CO.

Position the RH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
- Tighten to 10 N.m (89 lb-in).

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

Fig 71: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head

Courtesy of FORD MOTOR CO.

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

CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.

Fig 72: Identifying Tighten Sequence Of Valve Cover Bolts

Courtesy of FORD MOTOR CO.

Position the LH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
- Tighten to 10 N.m (89 lb-in).

NOTE: Do not reuse the O-ring seals.

NOTE: Lubricate the new O-ring seals with clean engine coolant prior to installation.

Fig 73: Sliding Coolant Tube Forward With O-Ring Seals Into Cylinder Block

Courtesy of FORD MOTOR CO.

Slide the coolant tube forward with the new O-ring seals into the cylinder block.
Install the coolant tube stud bolt.
- Tighten to 10 N.m (89 lb-in).
Fig 74: Identifying Coolant Tube Stud Bolt
Courtesy of FORD MOTOR CO.
Install the 2 knock sensors (KS) and the bolts.
- Tighten to 20 N.m (15 lb-ft).
Fig 75: Identifying Knock Sensors (KS)
Courtesy of FORD MOTOR CO.
Install the oil level indicator tube and the front bolt.
- Tighten to 25 N.m (18 lb-ft).
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.
Fig 76: Locating Front Oil Level Indicator Tube Bolt
Courtesy of FORD MOTOR CO.
Install the rear oil level indicator tube bolt.
- Tighten to 10 N.m (89 lb-in).
Fig 77: Locating Rear Oil Level Indicator Tube Bolt
Courtesy of FORD MOTOR CO.
Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.

NOTE: LH shown, RH similar.

Fig 78: Identifying Ignition Coils And Bolts

Courtesy of FORD MOTOR CO.

Install the 8 ignition coils and the 8 bolts.
- Tighten to 6 N.m (53 lb-in).
Install the LH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 N.m (18 lb-ft).
Fig 79: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
Courtesy of FORD MOTOR CO.
Connect the cylinder head temperature (CHT) sensor electrical connector.

Fig 80: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 4 RH ignition coil electrical connectors.

Fig 81: Locating Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the 2 engine wiring harness retainers from the RH valve cover studs.

Fig 82: Locating Engine Wiring Harness Retainers At RH Valve Cover
Courtesy of FORD MOTOR CO.
Connect the RH VCT solenoid electrical connector.

Fig 83: Locating Camshaft Timing (VCT) Solenoid Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the RH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 N.m (18 lb-ft).
Fig 84: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
Courtesy of FORD MOTOR CO.
Connect the RH CMP sensor electrical connector.

Fig 85: Identifying RH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Position a new oil cooler and install the threaded shaft.
- Tighten to 58 N.m (43 lb-ft).
Fig 86: Identifying Threaded Shaft
Courtesy of FORD MOTOR CO.
Connect the coolant hoses to the oil cooler.

Fig 87: Connecting Coolant Hoses To Oil Cooler
Courtesy of FORD MOTOR CO.
Connect the lower radiator hose to the oil filter adapter.

Fig 88: Connecting Lower Radiator Hose To Oil Filter Adapter
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 89: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Using a suitable floor crane, remove the engine from the engine stand.

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.

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.

Fig 90: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface

Courtesy of FORD MOTOR CO.

Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.

Fig 91: Locating Crankshaft Rear Seal Retainer Plate Bolts
Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown.
- Tighten to 10 N.m (89 lb-in).
Fig 92: Tightening Bolts In Sequence
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.

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.

Fig 93: Applying Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.

Fig 94: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Mating Surface

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
Install the oil pan gasket and the oil pan and loosely install the bolts.

Fig 95: Positioning New Oil Pan Gasket And Oil Pan
Courtesy of FORD MOTOR CO.
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 96: Identifying Oil Pan Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Fig 97: Using Special Tools To Install New Crankshaft Rear Seal

Courtesy of FORD MOTOR CO.

Using the special tools, install a new crankshaft rear seal.
Using the special tools, install a new crankshaft rear oil slinger.

Fig 98: Installing Crankshaft Rear Oil Slinger Using Special Tools
Courtesy of FORD MOTOR CO.
Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 N.m (59 lb-ft).
Fig 99: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts
Courtesy of FORD MOTOR CO.