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Section 875 (Engine - 4.0L (SOHC)): Assembly: Engine

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.
Special Tools

Illustration Tool Name Tool Number
GF0000230
 Camshaft Gear Holding Tool 303-564 (T97T-6256-B)
GF0000237
 Camshaft Gear Holding Tool Adapter 303-578 (T97T-6256-A)
GF0000236
 Camshaft Holding Tool 303-577 (T97T-6256-C)
GF0000234
 Camshaft Holding Tool Adapter 303-576 (T97T-6256-D)
GF0000290
 Crankshaft Damper Replacer 303-102 (T74P-6316-B)
GF0000232
 Crankshaft Holding Tool 303-573 (T97T-6303-A)
GF0000536
 Heavy Duty Floor Crane 014-00071
GF0000251
 Installer, Crankshaft Rear Oil Seal 303-579 (T97T-6701-A)
GF0000160
 Lifting Brackets, Engine 303-050 (T70P-6000)
GF0000291
 Piston Ring Compressor 303-D032 (D81L-6002-C)
GF0009422
 Rear Jackshaft Socket 303-634
GF0000250
 Service Set, Rear Oil Seal Replacer 303-S524 (T95T-6701-AR)
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3)
GF0000246
 Strap Wrench 303-D055 (85L-6000-A) or equivalent
GF0000231
 Timing Chain Tensioner 303-571 (T97T-6K254-A)
GF0000262
 Valve Spring Compressor 303-581 (T97T-6565-A)
Material

Item Specification
Motorcraft Metal Surface Cleaner
ZC-21		 WSE-M5B392-A
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil
XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalent		 WSS-M2C929-A
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Fig 1: 4.0L SOHC Engine - Upper Components
GF0009460Courtesy of FORD MOTOR CO.
Item Part Number Description
1 9D280 LH fuel rail
2 W500023 Bolt (4 required)
3 W711782 Bolt (2 required)
4 9G624 Fuel pressure relief valve
5 9E964 Fuel rail supply tube
6 W711782 Bolt
7 9D280 RH fuel rail
8 9F593 Fuel injector (6 required)
9 9Y476 Fuel vapor tube
10 9K479 Intake manifold
11 6763 Oil filler pipe
12 6582 Valve cover RH
13 6A258 Camshaft bearing cap (3 required)
14 6250 Camshaft RH
15 6A258 Camshaft bearing cap
16 18465 Heated PCV coolant hose
17 18696 Heater coolant inlet tube assembly
18 W500023 Bolt
19 17A084 Lifting eye RH
20 W500041 Bolt (2 required)
21 W701706 Nut (6 required)
22 9430 Exhaust manifold RH
23 9448 Exhaust manifold gasket RH
24 6K254 Timing chain tensioner RH
25 W703974 Spacer
26 W705495 Stud (6 required)
27 6051 Cylinder head gasket RH
28 6049 Cylinder head RH
29 W525966 Clamp (2 required)
30 8548 Coolant hose
31 8A586 Thermostat housing
32 W702527 Bolt (3 required)
33 W702341 Bolt (16 required)
34 6049 Camshaft bearing cap
35 6A274 Camshaft LH
36 6K254 Timing chain tensioner LH
37 6N091 Oil volume reduction plug
38 6U000 Bolt
39 12405 Spark plug (6 required)
40 6505 Exhaust valve (6 required)
41 6083 Cylinder head gasket LH
42 6507 Intake valve (6 required)
43 9J433 Differential pressure feedback EGR sensor
44 9E469 EGR tube
45 9G485 Adapter
46 9431 Exhaust manifold LH
47 W701706 Nut (6 required)
48 W500023 Bolt
49 9448 Exhaust manifold gasket LH
50 W705495 Stud (6 required)
51 W500041 Bolt (2 required)
52 17A084 Lifting eye LH
53 12A310 Ignition coil assembly
54 W500213 Bolt (2 required)
55 6571 Valve stem seal (12 required)
56 6513 Valve spring (12 required)
57 6C501 Lash adjuster (12 required)
58 6518 Valve spring retainer key (24 required)
59 6529 Roller follower (12 required)
60 6065 Cylinder head bolt (16 required)
61 6A536 Valve spring retainer seat (12 required)
62 6A258 Camshaft bearing cap (3 required)
63 6A505 Valve cover LH
64 14A004 Bracket
65 W500204 Bolt
66 W500204 Bolt
67 6B288 Camshaft position (CMP) sensor
Fig 2: 4.0L SOHC Engine - Front and Rear Components
GF0009461Courtesy of FORD MOTOR CO.
Item Part Number Description
68 6L621 Gasket
69 6884 Oil filter adapter
70 6895 Bolt
71 E853188 O-ring seal
72 6890 Adapter
73 6714 Oil filter
74 6M272 Jackshaft chain guide
75 6M278 Jackshaft thrust plate
76 6M263 Jackshaft
77 6C524 Jackshaft sprocket
78 6M276 Bolt
79 6M270 Jackshaft chain
80 W500012 Bolt (2 required)
81 6M271 Jackshaft chain tensioner
82 W702125 Bolt (2 required)
83 W500110 Bolt (2 required)
84 W500024 Bolt (5 required)
85 W702501 Stud
86 8507 Gasket
87 W500014 Bolt (12 required)
88 W500213 Bolt (2 required)
89 E800511 Bolt
90 6B321 Crankshaft pulley
91 6C315 Crankshaft position (CKP) sensor
92 8501 Coolant pump
93 6700 Crankshaft front seal
94 E804541 Stud (4 required)
95 6019 Front cover
96 6020 Gasket
97 6379 Bolt (8 required)
98 6375 Flexplate
99 6434 Spacer
100 6701 Crankshaft rear seal
101 6M296 Spacer
Fig 3: 4.0L SOHC Engine - Lower Components
GF0009462Courtesy of FORD MOTOR CO.
Item Part Number Description
102 6U000 Bolt
103 6M290 Camshaft drive cassette RH
104 12A699 Knock sensor (KS)
105 W702979 Crankshaft key
106 6306 Sprocket
107 6K350 Sprocket
108 6329 Crankshaft front main bearing cap
109 6345 Bolt (8 required)
110 W709211 Stud (2 required)
111 6F092 Cylinder block cradle
112 W503275 Bolt (20 required)
113 E822125 Nut
114 6734 Gasket
115 W702323 Bolt
116 E802185 Bolt
117 6675 Oil pan
118 W702323 Bolt (6 required)
119 6617 Oil pump screen and pickup tube
120 W709198 Bolt
121 E804588 Bolt
122 6C629 Spacer
123 6710 Gasket
124 6334 Crankshaft front intermediate main bearing cap
125 E804553 Screw (3 required)
126 6K790 Oil pickup adapter
127 W708582 Bolt (2 required)
128 6600 Oil pump
129 6A605 Oil pump intermediate shaft
130 6325 Crankshaft rear main bearing cap
131 6330 Crankshaft center main bearing cap
132 6A338 Crankshaft lower main bearing (3 required)
133 6A339 Crankshaft lower center main bearing
134 6303 Crankshaft
135 6333 Crankshaft upper main bearing (3 required)
136 6337 Crankshaft upper center main bearing
137 6010 Block
138 9278 Oil pressure sensor
139 W701473 Nut (12 required)
140 6210 Connecting rod bearing cap (6 required)
141 6211 Connecting rod bearings
142 6200 Connecting rod
143 6135 Piston pin
144 6159 Piston rings, oil control (2 required)
145 6152 Piston ring, lower compression
146 6214 Bolt (2 required)
147 6110 Piston
148 6161 Piston ring, oil control spacer
149 6150 Piston ring, upper compression
150 6754 Oil level indicator tube
151 W701723 Bolt
152 6750 Oil level indicator
153 W500024 Bolt
154 12270 Clamp
155 6846 Oil pump drive assembly
156 6M289 Camshaft drive cassette LH
157 6M276 Bolt
158 W500110 Bolt
159 W703167 Bolt
160 6U001 Bolt
161 W500225 Bolt
162 6M276 Bolt
CAUTION: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail.
NOTE: Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.
    NOTE: Lubricate the crankshaft main bearings with clean engine oil before installation.
  1. Install the crankshaft upper main bearings and the thrust bearing.
    2. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
    Fig 4: Locating Crankshaft Main Bearings
    GF0000285Courtesy of FORD MOTOR CO.
  2. Install the crankshaft.
    3. NOTE: The rear main bearing cap must be installed within 4 minutes after applying the silicone.
    Fig 5: Apply Silicone Gasket & Sealant To Rear Main Bearing Cap
    GF0000293Courtesy of FORD MOTOR CO.
  3. Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
    4. NOTE: Lubricate the crankshaft main bearings with clean engine oil before installation.
  4. Install the crankshaft lower main bearings in the main bearing caps.
  5. Install the main bearing caps.
    Fig 6: locating main bearing caps
    GF0000294Courtesy of FORD MOTOR CO.
  6. Tighten the main bearing cap bolts in 2 stages in the sequence shown.
    Fig 7: Identifying Main Bearing Cap Bolts Tightening Sequence
    GF0009463Courtesy of FORD MOTOR CO.
    • Stage 1: Tighten to 35 Nm (26 lb-ft).
    • Stage 2: Tighten an additional 57 degrees.
  7. Lubricate the piston rings with clean engine oil.
  8. Make sure that the piston rings are correctly spaced. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
    Fig 8: Locating Rubber Hose Pieces On Connecting Rod Bolts
    GF0000282Courtesy of FORD MOTOR CO.
    10. NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.
    NOTE: Lubricate the cylinder wall with clean engine oil.
    Fig 9: Installing Piston Using Special Tool
    GF0009464Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the pistons.
    11. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.
  11. Check the clearance of each connecting rod bearing. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  12. Rotate the crankshaft until the piston is at the bottom of its stroke.
    13. NOTE: For cylinders 1, 2 and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5 and 6, remove the opposite nut first.
    Fig 10: Locating Connecting Rod Nut
    GF0000295Courtesy of FORD MOTOR CO.
  13. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
  14. Tap the bolt on the nut until it can be removed by hand.
  15. Repeat previous 2 steps for the opposite bolt.
    Fig 11: Locating Opposite Bolt
    GF0000296Courtesy of FORD MOTOR CO.
  16. Install the new bolts, making certain that the bolt head is parallel to the sideward face of the connecting rod.
  17. Install the connecting rod cap in its original position.
    Fig 12: Locating Connecting Rod Cap
    GF0000297Courtesy of FORD MOTOR CO.
  18. Install and tighten the connecting rod nuts finger tight.
  19. Tighten the connecting rod nuts in 2 stages in pairs.
    Fig 13: Tightening Connecting Rod Nuts
    GF0000298Courtesy of FORD MOTOR CO.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  20. Repeat previous 4 steps for the remaining connecting rods.
  21. Rotate the crankshaft until No. 1 piston is at top dead center (TDC).
  22. Install the oil pump and the bolts.
    Fig 14: Locating Oil Pump & Bolts
    GF0009452Courtesy of FORD MOTOR CO.
    • Tighten to 19 Nm (14 lb-ft).
  23. Install the jackshaft.
    Fig 15: Locating Jackshaft
    GF0009455Courtesy of FORD MOTOR CO.
  24. Install the jackshaft thrust plate and the bolts.
    Fig 16: Locating Jackshaft Thrust Plate & Bolts
    GF0000280Courtesy of FORD MOTOR CO.
    • Tighten to 11 Nm (8 lb-ft).
  25. Install the jackshaft spacer.
    Fig 17: Locating Jackshaft Spacer
    GF0009456Courtesy of FORD MOTOR CO.
  26. Install the oil pump drive and the hold down.
    Fig 18: Locating Oil Pump Drive
    GF0000277Courtesy of FORD MOTOR CO.
    • Tighten to 19 Nm (14 lb-ft).
  27. Position the RH camshaft drive cassette and install the sprocket bolt. Do not tighten the bolt at this time.
    Fig 19: Locating RH Camshaft Drive Cassette Bolt
    GF0009454Courtesy of FORD MOTOR CO.
  28. Install the RH camshaft drive cassette bolt and spacer.
    Fig 20: Locating RH Camshaft Drive Cassette Bolt & Spacer
    GF0000276Courtesy of FORD MOTOR CO.
    • Tighten to 18 Nm (13 lb-ft).
  29. Install the front cassette and bolt.
    Fig 21: Locating Front Cassette & Bolt
    GF0000257Courtesy of FORD MOTOR CO.
    • Tighten to 19 Nm (14 lb-ft).
  30. Position the jackshaft sprocket and chain.
    Fig 22: Locating Jackshaft Chain And Sprockets
    G03914213Courtesy of FORD MOTOR CO.
  31. Install the chain guide and bolts.
    Fig 23: Locating Chain Guide & Bolts
    GF0000278Courtesy of FORD MOTOR CO.
    • Tighten to 19 Nm (14 lb-ft).
  32. Install the chain tensioner and the bolts.
    Fig 24: Locating Chain Tensioner & Bolts
    GF0000255Courtesy of FORD MOTOR CO.
    • Tighten to 9 Nm (80 lb-in).
  33. Install the bolt. Do not tighten at this time.
  34. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt.
    Fig 25: Locating Front Jackshaft Sprocket Bolt
    GF0000279Courtesy of FORD MOTOR CO.
    • Tighten to 20 Nm (15 lb-ft).
  35. Install the special tool on the rear of the jackshaft.
    Fig 26: Identifying Special Tool (303-634)
    GF0009465Courtesy of FORD MOTOR CO.
  36. Tighten the rear bolt an additional 90 degrees.
    Fig 27: Locating Rear Bolt
    GF0009466Courtesy of FORD MOTOR CO.
  37. Tighten the front bolt in 2 stages.
    Fig 28: Locating Front Bolt
    GF0000279Courtesy of FORD MOTOR CO.
    • Stage 1: Tighten to 45 Nm (33 lb-ft).
    • Stage 2: Tighten 90 degrees.
  38. Remove the special tool and install the rear jackshaft plug.
    Fig 29: Locating Rear Jackshaft Plug
    GF0000275Courtesy of FORD MOTOR CO.
  39. Position the front cover gasket and install the front cover and the fasteners.
    Fig 30: Locating Front Cover & Fasteners
    GF0009449Courtesy of FORD MOTOR CO.
    • Tighten to 19 Nm (14 lb-ft).
    40. CAUTION: Failure to back off the set screws may result in damage to the cylinder block cradle.
    NOTE: The set screw is shown from the top (crankshaft) side of the cylinder block cradle.
    Fig 31: Identifying Cylinder Block Cradle Boss
    GF0009467Courtesy of FORD MOTOR CO.
  40. Back the 8 set screws (7/16-inch Hex) off until they are below the cylinder block cradle boss.
    41. NOTE: If the cylinder block cradle gasket is not secured within 4 minutes of the sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow the metal surface cleaner 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 32: Locating Places For Applying Silicon
    GF0009468Courtesy of FORD MOTOR CO.
  41. Apply silicone in the 6 places shown.
  42. Position the cylinder block cradle and gasket assembly.
    Fig 33: Locating Cylinder Block Cradle & Gasket Assembly
    GF0000301Courtesy of FORD MOTOR CO.
  43. Install and hand-tighten the 20 bolts and 2 nuts.
    Fig 34: Locating Bolts & Nuts
    GF0000273Courtesy of FORD MOTOR CO.
  44. Install and hand-tighten the rear cylinder block cradle bolts.
    Fig 35: Locating Rear Cylinder Block Cradle Bolts
    GF0000302Courtesy of FORD MOTOR CO.
    45. NOTE: The cylinder block cradle to cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle under flush or 0.05 mm (0.002 in) cylinder block cradle protrusion.
    Fig 36: Locating Transmission Face Of Cylinder Block Cradle With Rear Face Of Cylinder Block
    GF0009469Courtesy of FORD MOTOR CO.
  45. Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.
  46. Tighten the 20 bolts and 2 nuts.
    Fig 37: Locating Bolts & Nuts
    GF0000273Courtesy of FORD MOTOR CO.
    • Tighten the nuts to 10 Nm (89 lb-in).
    • Tighten the bolts to 14 Nm (10 lb-ft).
  47. Tighten the rear cylinder block cradle bolts.
    Fig 38: Locating Rear Cylinder Block Cradle Bolts
    GF0000302Courtesy of FORD MOTOR CO.
    • Tighten to 9 Nm (80 lb-in).
  48. Tighten the 8 set screws (7/16-inch Hex).
    Fig 39: Locating Cylinder Block Cradle Rear Torx Bolts
    GF0009367Courtesy of FORD MOTOR CO.
    • Tighten to 3 Nm (27 lb-in).
  49. Install new seals on the 2 silver bolts and position them in the cylinder block cradle.
    Fig 40: Locating Silver-Colored Bolts And New Washer Seals
    GF0009368Courtesy of FORD MOTOR CO.
  50. Position the 6 remaining bolts.
    Fig 41: Positioning Six Remaining Bolts
    GF0009470Courtesy of FORD MOTOR CO.
  51. Tighten the cylinder block cradle inner bolts in 2 stages in the sequence shown.
    Fig 42: Identifying Cylinder Block Cradle Inner Bolts Tightening Sequence
    GF0009369Courtesy of FORD MOTOR CO.
    • Stage 1: Tighten to 15 Nm (11 lb-ft).
    • Stage 2: Tighten to 33 Nm (24 lb-ft).
    52. NOTE: The cylinder block cradle-to-cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle under flush or 0.05 mm (0.002 in) cylinder block cradle protrusion.
    Fig 43: Measuring Step Between Rear Face Of Cylinder Block & Transmission Face Of Cylinder Block Cradle
    GF0009471Courtesy of FORD MOTOR CO.
  52. Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.
    • Cradles that exceed protrusion specification must be removed and the appropriate assembly steps repeated.
    • Cradles that exceed the under flush specification may be repaired by installing shims (next step).
  53. Repair all assemblies that exceed under flush specification by installing shims on one or both sides of the cylinder block cradle.
    Fig 44: Locating Shims On Both Sides Of Cylinder Block Cradle
    GF0000303Courtesy of FORD MOTOR CO.
  54. Install the oil pump screen cover and tube and bolt.
    Fig 45: Locating Oil Pump Screen Cover And Bolt
    GF0009451Courtesy of FORD MOTOR CO.
    • Tighten to 10 Nm (89 lb-in).
  55. Install the gasket, oil pan and the bolts.
    Fig 46: Locating Oil Pan Bolts
    GF0009450Courtesy of FORD MOTOR CO.
    • Tighten to 11 Nm (8 lb-ft).
  56. Install the oil filter adapter.
    Fig 47: Locating Oil Filter Adapter
    GF0000274Courtesy of FORD MOTOR CO.
    • Tighten to 57 Nm (42 lb-ft).
  57. Position the coolant pump and install the bolts.
    Fig 48: Locating Coolant Pump Bolts
    GF0009446Courtesy of FORD MOTOR CO.
    • Tighten to 10 Nm (89 lb-in).
    58. NOTE: LH shown, RH similar.
    Fig 49: Locating Cylinder Head Gaskets
    GF0009472Courtesy of FORD MOTOR CO.
  58. Install the cylinder head gaskets.
    59. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
    Fig 50: Identifying Tightening Sequence Of 12-MM Bolts
    GF0009327Courtesy of FORD MOTOR CO.
  59. Install the LH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 12 Nm (9 lb-ft).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
  60. Install the 2 new 8-mm bolts.
    Fig 51: Locating 8-Mm Bolts
    GF0009328Courtesy of FORD MOTOR CO.
    • Tighten to 32 Nm (24 lb-ft).
  61. Tighten the bolts in the sequence shown in 2 stages.
    Fig 52: Identifying Tightening Sequence Of 12-MM Bolts
    GF0009327Courtesy of FORD MOTOR CO.
    • Stage 1: Tighten 90 degrees.
    • Stage 2: Tighten an additional 90 degrees.
    62. NOTE: New cylinder head bolts must be installed. They are a torque to yield design and cannot be reused.
    Fig 53: Identifying Cylinder Head Bolts Tightening Sequence
    GF0009330Courtesy of FORD MOTOR CO.
  62. Install the RH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
    • Stage 1:Tighten to 12 Nm (9 lb-ft).
    • Stage 2:Tighten to 25 Nm (18 lb-ft).
  63. Install the 2 new 8-mm bolts.
    Fig 54: Locating 8-Mm Bolts
    GF0009328Courtesy of FORD MOTOR CO.
    • Tighten to 32 Nm (24 lb-ft).
  64. Tighten the bolts in the sequence shown in 2 stages.
    Fig 55: Identifying Cylinder Head Bolts Tightening Sequence
    GF0009330Courtesy of FORD MOTOR CO.
    • Stage 1: Tighten 90 degrees.
    • Stage 2: Tighten an additional 90 degrees.
  65. Using the special tool, install the crankshaft pulley.
    Fig 56: Installing Crankshaft Pulley Using Special Tool
    GF0009315Courtesy of FORD MOTOR CO.
    66. NOTE: A new bolt must be used each time it is removed.
    Fig 57: Holding Crankshaft Pulley Using Special Tool
    G03946937Courtesy of FORD MOTOR CO.
  66. Install the crankshaft pulley bolt and tighten in 2 stages.
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  67. Position the RH camshaft sprocket in the chain and install it on the camshaft.
    Fig 58: Locating RH Camshaft Sprocket In Chain
    GF0009473Courtesy of FORD MOTOR CO.
    68. NOTE: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
    Fig 59: Locating RH Camshaft Sprocket Bolt
    GF0000269Courtesy of FORD MOTOR CO.
  68. Install the RH camshaft sprocket bolt.
  69. Install the RH chain guide bolt.
    Fig 60: Locating RH Chain Guide Bolt
    GF0000270Courtesy of FORD MOTOR CO.
    • Tighten to 10 Nm (89 lb-in).
  70. Position the LH camshaft sprocket in the chain and install it on the camshaft.
    Fig 61: Positioning LH Camshaft Sprocket In Chain
    GF0009474Courtesy of FORD MOTOR CO.
    71. NOTE: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
    Fig 62: Locating LH Camshaft Sprocket Bolt
    GF0000261Courtesy of FORD MOTOR CO.
  71. Install the LH camshaft sprocket bolt.
  72. Install the chain guide bolt.
    Fig 63: Locating Chain Guide Bolt
    GF0000256Courtesy of FORD MOTOR CO.
    • Tighten to 12 Nm (9 lb-ft).
  73. Turn the crankshaft one revolution clockwise.
    74. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.
    NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the engine at TDC.
    Fig 64: Identifying Special Tool (303-573)
    G03946899Courtesy of FORD MOTOR CO.
  74. Install the special tool.
    75. NOTE: Camshaft timing slots are off-center.
    Fig 65: Identifying Special Tools (303-576, 303-577)
    G03946903Courtesy of FORD MOTOR CO.
  75. Position the camshaft timing slots below centerline of camshaft and install the special tools on the front of the RH cylinder head.
    76. NOTE: Leave the top 2 special tool clamp bolts loose.
    Fig 66: Identifying Special Holding Tool
    G03946909Courtesy of FORD MOTOR CO.
  76. Install the special tools on the rear of the RH cylinder head.
  77. Install the special tool.
    Fig 67: Identifying Special Tool (303-571)
    G03946905Courtesy of FORD MOTOR CO.
    78. NOTE: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
  78. Tighten the bolts.
    • Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in).
      Fig 68: Identifying Camshaft Bolt & Clamp Bolts
      G03947018Courtesy of FORD MOTOR CO.
    • Tighten the camshaft bolt to 85 Nm (63 lb-ft).
  79. Install the RH camshaft tensioner.
    Fig 69: Identifying Special Tool (303-571)
    G03946905Courtesy of FORD MOTOR CO.
    • Tighten to 44 Nm (32 lb-ft).
    80. NOTE: Do not tighten the special tool top 2 clamp bolts. Camshaft sprocket must rotate freely.
    Fig 70: Identifying Special Holding Tool
    G03946909Courtesy of FORD MOTOR CO.
  80. Install the special tools on the front of the LH cylinder head.
    81. NOTE: Camshaft timing slots are off-center.
    Fig 71: Identifying Special Tools (303-576, 303-577)
    G03946903Courtesy of FORD MOTOR CO.
  81. Position the camshaft timing slots below centerline of camshaft and install the special tools on the rear of the LH cylinder head.
  82. Install the special tool.
    Fig 72: Identifying Special Tool (303-571)
    GF0000238Courtesy of FORD MOTOR CO.
  83. Tighten the bolts.
    • Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in).
      Fig 73: Identifying Camshaft Bolt & Clamp Bolts
      G03947018Courtesy of FORD MOTOR CO.
    • Tighten the camshaft bolt.
    • Tighten to 85 Nm (63 lb-ft).
  84. Install the LH camshaft tensioner.
    Fig 74: Locating Camshaft Tensioner
    G03913851Courtesy of FORD MOTOR CO.
    • Tighten to 44 Nm (32 lb-ft).
  85. Rotate the crankshaft until the cam lobe is in the UP position.
    Fig 75: Locating Crankshaft Lobe
    GF0009348Courtesy of FORD MOTOR CO.
    86. Fig 76: Locating Camshaft Roller Follower And Special Tools
    GF0009447Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the parts with clean engine oil prior to installing.
  86. Using the special tool, install the roller followers in their original positions.
  87. Clean and inspect the LH and RH exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  88. Install 6 new LH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
  89. Install a new gasket, the LH exhaust manifold and new nuts.
    Fig 77: Locating LH Exhaust Manifold Nuts
    GF0009475Courtesy of FORD MOTOR CO.
    • Tighten to 22 Nm (16 lb-ft).
  90. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
  91. Install a new gasket, the RH exhaust manifold and new nuts.
    Fig 78: Locating RH Exhaust Manifold Nuts
    GF0009476Courtesy of FORD MOTOR CO.
    • Tighten to 22 Nm (16 lb-ft).
    92. NOTE: Prior to installation, use metal surface cleaner to clean mating surfaces.
    Fig 79: Locating Knock Sensor (KS) Bolt
    GF0009443Courtesy of FORD MOTOR CO.
  92. Install the knock sensor (KS) and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
  93. Install the oil level indicator tube and the bolt.
    Fig 80: Locating Oil Level Indicator Tube Bolt
    GF0009442Courtesy of FORD MOTOR CO.
    • Tighten to 10 Nm (89 lb-in).
  94. Install the thermostat housing.
    • Position the housing and the bypass hose and install the bolts.
      Fig 81: Identifying Bypass Hose Clamp & Housing
      GF0009441Courtesy of FORD MOTOR CO.
      • Tighten to 11 Nm (8 lb-ft).
    • Position the bypass hose clamp.
  95. Install the gasket, the RH valve cover and the bolts.
    Fig 82: Locating Valve Covers & Gasket
    GF0009440Courtesy of FORD MOTOR CO.
    • Tighten to 10 Nm (89 lb-in).
  96. Install the gasket, the LH valve cover and the bolts.
    Fig 83: Locating LH Valve Cover & Gasket
    GF0009439Courtesy of FORD MOTOR CO.
    • Tighten to 10 Nm (89 lb-in).
  97. Install the fuel rail and the fuel injectors as an assembly. Install the fuel rail bolts.
    Fig 84: Locating Fuel Rail Bolts
    GF0009438Courtesy of FORD MOTOR CO.
    • Tighten to 23 Nm (17 lb-ft).
  98. Install the EGR valve tube to the exhaust manifold.
    Fig 85: Locating EGR Tube From Exhaust Manifold
    GF0009437Courtesy of FORD MOTOR CO.
    • Tighten to 34 Nm (25 lb-ft).
  99. Position the engine wiring harness.
  100. Connect new wiring harness retainers.
    Fig 86: Locating Wiring Harness Anchors
    GF0009436Courtesy of FORD MOTOR CO.
  101. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 87: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    GF0009435Courtesy of FORD MOTOR CO.
  102. Position the coolant tube and bracket, the PCV hose-to-intake manifold fitting and the PCV hose as an assembly and install the bolts.
    Fig 88: Locating Coolant Tube Bracket Retaining Bolts
    GF0009432Courtesy of FORD MOTOR CO.
    • Tighten the large bolt to 28 Nm (21 lb-ft) and the small bolt to 23 Nm (17 lb-ft).
  103. Attach the wiring harness retainer.
    Fig 89: Detaching Wiring Harness Retainer And Removing Coolant Tube And Bracket Assembly
    GF0009434Courtesy of FORD MOTOR CO.
  104. Connect the coolant hose.
    Fig 90: Locating Coolant Hose
    GF0009433Courtesy of FORD MOTOR CO.
  105. Connect the coolant hose.
    Fig 91: Locating Coolant Hose
    GF0009431Courtesy of FORD MOTOR CO.
  106. Position the bracket and install the bolt.
    Fig 92: Locating Bracket & Bolt
    GF0009430Courtesy of FORD MOTOR CO.
    • Tighten to 28 Nm (21 lb-ft).
  107. Connect the KS and engine coolant temperature (ECT) sensor electrical connectors.
    Fig 93: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connectors
    GF0009429Courtesy of FORD MOTOR CO.
  108. Attach the 2 wiring harness retainers to the valve cover studs and connect the 6 fuel injector electrical connectors.
    Fig 94: Locating Wiring Harness Retainers & Valve Cover Studs
    GF0009428Courtesy of FORD MOTOR CO.
  109. Connect the camshaft position (CMP) sensor and differential pressure feedback EGR sensor electrical connectors. Attach the wiring harness retainer. Position the electrical connector bracket and install the bolt.
    Fig 95: Locating Camshaft Position (CMP) Sensor
    GF0009427Courtesy of FORD MOTOR CO.
    • Tighten to 6 Nm (53 lb-in).
  110. Connect the PCV valve hose and electrical connector.
    Fig 96: Locating PCV Valve Hose & Electrical Connector
    GF0009426Courtesy of FORD MOTOR CO.
  111. Attach the electrical connector. Position the ground wire and install the bolt.
    Fig 97: Locating Ground Wire & Bolt
    GF0009425Courtesy of FORD MOTOR CO.
    • Tighten to 25 Nm (18 lb-ft).
  112. Install the generator bracket.
    • Install the generator bracket and bolts.
      Fig 98: Locating Generator Mounting Bracket Bolts
      GF0009477Courtesy of FORD MOTOR CO.
      • Tighten to 42 Nm (31 lb-ft).
    • Install the accessory drive belt tensioner and bolt.
      • Tighten to 47 Nm (35 lb-ft).
    113. NOTE: The lifting brackets should be installed on the exhaust manifold studs for No. 3 and No. 4 cylinders.
  113. Install the Engine Lifting Brackets.
  114. Install the Spreader Bar to the Engine Lifting Brackets.
  115. Attach a floor crane to the Spreader Bar and remove the engine from the engine stand.
    116. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface cleaner.
  116. Lubricate the crankshaft rear seal with clean engine oil.
  117. Install the special tools.
    Fig 99: Identifying Special Tool (303-527, 303-528)
    GF0009374Courtesy of FORD MOTOR CO.
  118. Position the crankshaft rear seal.
    Fig 100: Identifying Crankshaft Rear Seal, Special Tool (303-527, 303-528)
    GF0009375Courtesy of FORD MOTOR CO.
  119. Using the special tool, install the crankshaft rear seal.
    Fig 101: Installing Crankshaft Rear Oil Seal Using Special Tool
    GF0009376Courtesy of FORD MOTOR CO.
  120. Install the crankshaft spacer.
  121. Install the crankshaft spacer plate.
    122. NOTE: Special bolts are used for flexplate or flywheel installation. Do not use standard bolts.
    Fig 102: Identifying Flywheel Bolts Tightening Sequence
    GF0009371Courtesy of FORD MOTOR CO.
  122. Install the flexplate or flywheel. Tighten the bolts in 3 stages in the sequence shown.
    • Stage 1: Tighten to 13 Nm (10 lb-ft).
    • Stage 2: Tighten to 50 Nm (37 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
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