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

NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.

NOTE: The front bulkhead does not have an oil squirter.

Install the 4 oil squirters.
- Tighten to 4 Nm (35 lb-in).
  
  Fig 1: Locating Oil Squirters
  Courtesy of FORD MOTOR CO.
Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.

Fig 2: Measuring Crankshaft Main Bearing Journal Diameters In At Least 2 Directions And Record Smallest Diameter For Each Journal
Courtesy of FORD MOTOR CO.
Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.

Fig 3: Positioning Main Bearing Beam In Engine Block With Main Bearing Beam Mounted Flush With Rear Face Of Engine Block
Courtesy of FORD MOTOR CO.
Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
- Tighten the bolts in the sequence shown in illustration in 3 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 4: Identifying Main Bearing Beam Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Measure each crankshaft block main bearing bore diameter.
- Remove the bolts and the main bearing beam.
- Discard the main bearing beam bolts.
  
  Fig 5: Identifying Crankshaft Block Main Bearing Bore Diameter
  Courtesy of FORD MOTOR CO.
Using the chart in illustration, select the crankshaft main bearings.

Fig 6: Crankshaft Main Bearings Chart
Courtesy of FORD MOTOR CO.

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

Using the original connecting rod cap bolts, install the connecting caps and bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
- Remove the bolts and the connecting rod cap.
- Discard the connecting rod cap bolts.
  
  Fig 7: Identifying Connecting Rod Large End Bore Measuring Directions
  Courtesy of FORD MOTOR CO.
Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.

Fig 8: Measuring Crankshaft Connecting Rod Bearing Journal Diameters In At Least 2 Directions
Courtesy of FORD MOTOR CO.
Using the chart in illustration, select the correct connecting rod bearings for each crankshaft connecting rod journal.

Fig 9: Connecting Rod Bearings Chart
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.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

NOTE: The center bulkhead is the thrust bearing.

Fig 10: Locating Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

Fig 11: Locating Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.

Fig 12: Locating Crankshaft In Cylinder Block
Courtesy of FORD MOTOR CO.
Lubricate the 10 main bearing beam side fit surfaces (front 2 shown in illustration) with clean engine oil.

Fig 13: Locating Main Bearing Beam Side Fit Surfaces
Courtesy of FORD MOTOR CO.
Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.

Fig 14: Positioning Main Bearing Beam In Engine Block With Main Bearing Beam Mounted Flush With Rear Face Of Engine Block
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.

NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

Install and tighten the 10 main bearing beam bolts.
- Tighten the bolts in the sequence shown in illustration in 3 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 15: Identifying Main Bearing Beam Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
  
  Fig 16: Measuring Crankshaft End Play
  Courtesy of FORD MOTOR CO.

NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
- When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
- The position of the upper and lower compression ring gaps are not controlled for installation.
  
  Fig 17: Identifying Piston Ring Compressor And Connecting Rod Installer
  Courtesy of FORD MOTOR CO.

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

NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.

NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

Install the connecting rod caps and bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 18: Locating Connecting Rod Caps Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) may result in damage to the engine.

NOTE: Turn the crankshaft in the normal direction of rotation only, or the engine may be damaged.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
Remove the timing peg plug.

Fig 19: Locating Timing Peg Plug
Courtesy of FORD MOTOR CO.

NOTE: The Crankshaft Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain in the TDC position during the crankshaft pulley removal and installation.

Fig 20: Locating Crankshaft Timing Peg

Courtesy of FORD MOTOR CO.

Install the Crankshaft Timing Peg.

NOTE: Clean the sealing surface with metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep.

Position the oil pump assembly and tighten the 4 bolts in the sequence shown in illustration, in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
  
  Fig 21: Identifying Oil Pump Assembly Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Clean the sealing surface with metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep.

Position a new oil pump pickup tube gasket and the pickup tube, and tighten the 4 bolts in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 22: Identifying Oil Pump Pickup Tube Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Using the Crankshaft Rear Main Oil Seal Installer, install the a new crankshaft rear seal and retainer plate assembly.

Fig 23: Installing Crankshaft Rear Seal With Retainer Plate Onto Crankshaft
Courtesy of FORD MOTOR CO.
Tighten the 6 crankshaft rear seal and retainer plate assembly bolts in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 24: Identifying Crankshaft Rear Seal And Retainer Plate 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 sealant.

NOTE: Clean the sealing surface with metal surface prep and silicone gasket remover. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep and the silicone gasket remover.

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. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the 13 oil pan bolts in the sequence shown in illustration.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 25: Identifying Oil Pan 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.

Fig 26: Locating Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.

NOTE: Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.

Fig 27: Locating Silicone Gasket And Sealant Applying Locations

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the locations shown in illustration.
Install a new cylinder head gasket.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

NOTE: Lubricate the cylinder head bolts with clean engine oil.

Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in illustration, in 5 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Tighten an additional 90 degrees (one-fourth turn).
- Stage 5: Tighten an additional 90 degrees (one-fourth turn).
  
  Fig 28: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Install the camshafts with the alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position may cause severe damage to the valves and pistons.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.

Install the camshafts and bearing caps in their original location and orientation. Tighten the 20 bearing cap bolts in the sequence shown in illustration in 3 stages:
- Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
- Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
- Stage 3: Tighten the bolts to 16 Nm (142 lb-in).
  
  Fig 29: Identifying Bearing Cap Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. The new diamond washers must be installed correctly, or severe engine damage may result.

Install the new diamond washers and the oil pump chain and sprockets.
- The crankshaft sprocket flange must be facing away from the engine block.
  
  Fig 30: Locating Crankshaft Sprocket Flange
  Courtesy of FORD MOTOR CO.

NOTE: The oil pump chain sprocket must be held in place.

Tighten the oil pump sprocket bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 31: Locating Oil Pump Sprocket Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump chain drive tensioner shoulder bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 32: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt and tighten the tensioner bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 33: Locating Oil Pump Chain Tensioner, Tensioner Spring And Tensioner Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Sprockets must turn freely on the camshafts.

Fig 34: Locating Sprocket Bolts

Courtesy of FORD MOTOR CO.

NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

Position the camshaft sprockets and loosely install the bolts. Do not tighten the sprocket bolts at this time.

NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Fig 35: Compressing Timing Chain Tensioner Plunger

Courtesy of FORD MOTOR CO.

Using the edge of a vise, compress the timing chain tensioner plunger.
Using a small pick, push back and hold the ratchet mechanism.

Fig 36: Pushing Back And Hold Ratchet Mechanism
Courtesy of FORD MOTOR CO.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 37: Pushing Ratchet Arm Back Into Tensioner Housing
Courtesy of FORD MOTOR CO.
Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

Fig 38: Installing Paper Clip Into Hole In Tensioner Housing
Courtesy of FORD MOTOR CO.
Install the timing chain.

Fig 39: Locating Timing Chain
Courtesy of FORD MOTOR CO.
Position the timing chain guides and install the 2 LH guide bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 40: Locating Timing Chain Guides And LH Guide Bolts
  Courtesy of FORD MOTOR CO.
Install the timing chain tensioner and the 2 bolts. Remove the paper clip to apply tension to the timing chain.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 41: Locating Timing Chain Tensioner Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage.

Fig 42: Identifying Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

Install the Camshaft Alignment Plate in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage.

NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.

Tighten the camshaft sprocket bolts.
- Tighten to 72 Nm (53 lb-ft).
  
  Fig 43: Locating Camshaft Sprocket Bolts
  Courtesy of FORD MOTOR CO.

Clean the engine front cover gasket surface with silicone gasket remover and metal surface prep.

Fig 44: Locating Bead Of Silicone Gasket And Sealant On Front Cover

Courtesy of FORD MOTOR CO.

Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.

Fig 45: Locating Silicone Gasket And Sealant Applying Locations

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the locations shown in illustration.

Install the front cover. Tighten the bolts in the sequence shown in illustration in 3 stages.
- Stage 1: Tighten the seventeen 8-mm bolts and the stud bolt to 10 Nm (89 lb-in).
- Stage 2: Tighten the 10-mm bolt to 25 Nm (18 lb-ft).
- Stage 3: Tighten the two 13-mm bolts to 48 Nm (35 lb-ft).
  
  Fig 46: Identifying Front Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the crankshaft front seal with clean engine oil.

Fig 47: Installing Crankshaft Front Seal

Courtesy of FORD MOTOR CO.

Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.

NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil to the seal area prior to installing.

Fig 48: Locating Crankshaft Pulley And Hole In Pulley At 6 O'Clock Position

Courtesy of FORD MOTOR CO.

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.

NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Fig 49: Locating Standard 6 mm x 18 mm Bolt In Crankshaft Pulley Hole

Courtesy of FORD MOTOR CO.

Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.

NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be held in place with the Drive Pinion Flange Holding Fixture and the Adapter for 205-126 and the bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).
- Stage 2: Rotate an additional 90 degrees.
  
  Fig 50: Locating Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.
Remove the 6 mm x 18 mm bolt.

Fig 51: Locating 6 mm x 18 mm Bolt In Crankshaft Pulley Hole
Courtesy of FORD MOTOR CO.
Remove the Crankshaft Timing Peg.

Fig 52: Removing Crankshaft Timing Peg Using Special Tool 303-465
Courtesy of FORD MOTOR CO.
Remove the Camshaft Alignment Plate.

Fig 53: Identifying Camshaft Alignment Plate In Slots On Rear Of Both Camshafts
Courtesy of FORD MOTOR CO.

NOTE: Only turn the crankshaft in the normal direction of rotation.

Turn the crankshaft clockwise one and three-fourths turn.
Install the Crankshaft Timing Peg.

Fig 54: Installing Crankshaft Timing Peg Using Special Tool 303-465
Courtesy of FORD MOTOR CO.

NOTE: Only turn the crankshaft in the normal direction of rotation.

Fig 55: Locating Crankshaft Timing Peg

Courtesy of FORD MOTOR CO.

Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft Timing Peg.

NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur.

Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, correct the engine timing.
  
  Fig 56: Locating 6 mm x 18 mm Bolt In Crankshaft Pulley Hole
  Courtesy of FORD MOTOR CO.
Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, correct the engine timing.
  
  Fig 57: Identifying Camshaft Alignment Plate
  Courtesy of FORD MOTOR CO.
Remove the Camshaft Alignment Plate.

Fig 58: Identifying Camshaft Alignment Plate
Courtesy of FORD MOTOR CO.
Position a new Crankshaft Position (CKP) sensor and loosely install the 2 bolts.

Fig 59: Locating Crankshaft Position Sensor Bolts
Courtesy of FORD MOTOR CO.
Adjust the CKP with the Crankshaft Sensor Aligner, the tool must engage a tooth of the vibration damper, and tighten the 2 bolts.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 60: Identifying Crankshaft Sensor Aligner Tool
  Courtesy of FORD MOTOR CO.
Remove the 6 mm x 18 mm bolt.

Fig 61: Locating Standard 6 mm x 18 mm Bolt In Crankshaft Pulley Hole
Courtesy of FORD MOTOR CO.
Remove the Crankshaft Timing Peg.

Fig 62: Removing Crankshaft Timing Peg
Courtesy of FORD MOTOR CO.
Install the timing peg plug.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 63: Locating Timing Peg Plug
  Courtesy of FORD MOTOR CO.

Clean the valve cover gasket sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.

Fig 64: Locating Silicone Gasket And Sealant Applying Locations

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the locations shown in illustration.

Install the valve cover and the 14 fasteners.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 65: Identifying Valve Cover Fasteners Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the following:
1. Crankshaft Position (CKP) sensor and the bolt
  - Tighten to 7 Nm (62 lb-in).
2. Cylinder Head Temperature (CHT) sensor
  - Tighten to 12 Nm (106 lb-in).
3. Spark plugs
  - Tighten to 15 Nm (133 lb-in).
    
    Fig 66: Identifying CKP Sensor Bolt, CHT Sensor And Spark Plugs
    Courtesy of FORD MOTOR CO.

NOTE: Lubricate the coolant pump O-ring seal with clean engine coolant prior to assembly.

Using a new O-ring seal, install the coolant pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 67: Locating Coolant Pump Bolts
  Courtesy of FORD MOTOR CO.
Install the coolant pump pulley and the 3 bolts.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 68: Locating Coolant Pump Pulley Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the fuel injector O-ring seals with clean engine oil prior to installation.

Using new O-ring seals, install the fuel rail and fuel injectors as an assembly, the ground strap and the bolt.
- Tighten the 2 fuel rail bolts to 25 Nm (18 lb-ft).
- Tighten ground strap bolt to 10 Nm (89 lb-in).
  
  Fig 69: Locating Fuel Rail With Injectors Bolts And Ground Strap
  Courtesy of FORD MOTOR CO.
Install the left motor mount and the 4 bolts.
- Tighten to 49 Nm (36 lb-ft).
  
  Fig 70: Locating Left Motor Mount Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.

Install the crankcase vent oil separator, the KS and the 9 bolts.
- Tighten the KS bolt to 20 Nm (177 lb-in).
- Tighten the 8 crankcase vent oil separator bolts to 10 Nm (89 lb-in).
  
  Fig 71: Locating Crankcase Vent Oil Separator Bolts And KS
  Courtesy of FORD MOTOR CO.

Using a new gasket, install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 72: Locating Thermostat Housing Bolts
  Courtesy of FORD MOTOR CO.
Install the ignition coil and the 4 bolts.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 73: Locating Ignition Coil Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots prior to installation.

Connect the spark plug wires to the spark plugs.
Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.

Fig 74: Locating Valve Cover Studs
Courtesy of FORD MOTOR CO.
Connect the ignition coil and the CHT sensor electrical connectors. Position the CHT sensor cover.

Fig 75: Locating Ignition Coil And CHT Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the fuel injector electrical connectors and attach the wiring harness pin-type retainers.

Fig 76: Locating Fuel Injector Electrical Connectors And Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Inspect and install new intake manifold gaskets, if necessary.

Fig 77: Locating Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.

NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

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.

Install the intake manifold and the 5 bolts.
- Tighten to 18 Nm (159 lb-in).
  
  Fig 78: Locating Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.
Install the EGR tube.
- Install the EGR tube bracket and the bolt to the intake manifold.
  - Tighten to 10 Nm (89 lb-in).
- Connect the EGR tube to the cylinder head.
  - Tighten to 55 Nm (41 lb-ft).
    
    Fig 79: Locating EGR Tube
    Courtesy of FORD MOTOR CO.
Connect the EGR tube to the intake manifold.
- Tighten to 18 Nm (159 lb-in).
  
  Fig 80: Locating EGR Tube Bolts
  Courtesy of FORD MOTOR CO.
Attach the engine wiring harness pin-type retainers to the intake manifold.
Connect the CMP sensor electrical connector and the PCV hose.

Fig 81: Locating CMP Sensor Electrical Connector And PCV Hose
Courtesy of FORD MOTOR CO.
Install the engine wiring harness connector bracket, the 3 bolts and connect the KS electrical connector.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 82: Locating Engine Wiring Harness Connector Bracket Bolts And KS Electrical Connector
  Courtesy of FORD MOTOR CO.
Connect the CKP sensor electrical connection and attach the wiring pin-type retainers.

Fig 83: Locating CKP Sensor Electrical Connection And Wiring Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Connect the following electrical connectors:
- Manifold Absolute Pressure (MAP) sensor
- Throttle Position (TP) sensor
- Idle Air Control (IAC) valve
  
  Fig 84: Locating MAP Sensor Connector, TP Sensor Connector And IAC Valve Connector
  Courtesy of FORD MOTOR CO.
Install the power steering pump assembly and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 85: Locating Power Steering Pump Assembly Bolts
  Courtesy of FORD MOTOR CO.

Install the EGR valve.
1. Using a new gasket, position the EGR valve and install the 2 bolts.
  - Tighten to 20 Nm (177 lb-in).
2. Connect the coolant hose.
3. Connect the electrical connector.
  
  Fig 86: Identifying EGR Valve Bolts, Coolant Hose And Electrical Connector
  Courtesy of FORD MOTOR CO.

Install the rear coolant outlet pipe.
1. Using a new gasket, install the rear coolant outlet pipe and the 4 bolts.
  - Tighten to 10 Nm (89 lb-in).
2. Connect the coolant hose.
  
  Fig 87: Identifying Rear Coolant Outlet Pipe Bolts And Coolant Hose
  Courtesy of FORD MOTOR CO.
If equipped, install the block heater.

Fig 88: Locating Block Heater
Courtesy of FORD MOTOR CO.
Install 7 new exhaust manifold-to-cylinder head studs.
- Tighten to 17 Nm (150 lb-in).
Position a new gasket and install the exhaust manifold and 7 new nuts.
- Tighten to 54 Nm (40 lb-ft).
  
  Fig 89: Locating Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.
Position the coolant tube assembly and install the 2 nuts.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 90: Locating Coolant Tube Assembly Nuts
  Courtesy of FORD MOTOR CO.
Connect the coolant hose to the thermostat and the PCV fitting on the intake manifold.

Fig 91: Locating Coolant Hose And PCV Fitting
Courtesy of FORD MOTOR CO.
Position the right motor mount and install the 4 bolts.
- Tighten to 49 Nm (36 lb-ft).
  
  Fig 92: Locating Right Motor Mount Bolts
  Courtesy of FORD MOTOR CO.
Position the generator and support bracket assembly and install the 5 bolts in the sequence shown in illustration, in 2 stages.
- Stage 1: Install finger-tight.
- Stage 2: Tighten to 47 Nm (35 lb-ft).
  
  Fig 93: Identifying Generator And Support Bracket Assembly Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Position the A/C compressor and install the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 94: Locating A/C Compressor Bolts
  Courtesy of FORD MOTOR CO.

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

Position the front coolant outlet pipe and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 95: Locating Front Coolant Outlet Pipe Bolts
  Courtesy of FORD MOTOR CO.

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

Install the engine oil level indicator tube and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 96: Locating Engine Oil Level Indicator Tube And Bolt
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt.

Fig 97: Locating Drive Belt & Belt Routing
Courtesy of FORD MOTOR CO.
Using the Spreader Bar and the Floor Crane, remove the engine from the Engine Stand.
Position the flywheel or the flexplate and loosely install the 6 bolts.
Using the Flywheel Locking Tool, tighten the 6 bolts in the sequence shown in illustrations, in 3 stages.
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (59 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).
  
  Fig 98: Identifying Flywheel Locking Tool And Flywheel Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Vehicles with manual transmission
Lubricate the transmission input shaft pilot bearing with front axle grease.

Fig 99: Locating Transmission Input Shaft Pilot Bearing
Courtesy of FORD MOTOR CO.
Adjust the clutch pressure plate.
1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
  
  Fig 100: Compressing Tension Springs
  Courtesy of FORD MOTOR CO.
Using the Clutch Disc Aligner, position the clutch disc on the flywheel.

Fig 101: Positioning Clutch Disc On Flywheel
Courtesy of FORD MOTOR CO.

NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.

Position the clutch pressure plate and install the 6 bolts. Tighten the bolts in a star pattern sequence.
- Tighten to 32 Nm (24 lb-ft).
  
  Fig 102: Locating Clutch Pressure Plate Bolts
  Courtesy of FORD MOTOR CO.