Section 1325 (Engine Mechanical - 4.6L (3V)): Assembly: Engine

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

Fig 1: Exploded View Of Engine - Upper End

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Engine - Lower End

Courtesy of FORD MOTOR CO.

All vehicles 

1. Record the main bearing code found on the front of the engine block.
Fig 3: Identifying Main Bearing Code Found On Front Of Engine Block
Courtesy of FORD MOTOR CO.
2. Record the main bearing code found on the back of the crankshaft.
Fig 4: Identifying Main Bearing Code Found On Back Of Crankshaft
Courtesy of FORD MOTOR CO.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
   • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 1 crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2".
   • Repeat this process for the remaining 4 main bearings.
Fig 5: Bearing Select Fit Chart (Standard Bearings)
Courtesy of FORD MOTOR CO.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
Fig 6: Bearing Select Fit Chart (Oversize Bearings)
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.
5. Install the crankshaft main bearings.
   • Install the crankshaft upper main bearings into the cylinder block.
   • Install the crankshaft lower main bearings into the bearing caps.
   • Make sure all oil passages are aligned.
   • Lubricate all main bearings with clean engine oil.
6. Lubricate the crankshaft bearing journals with clean engine oil. Install the crankshaft onto the upper crankshaft main bearings.
Fig 7: Locating Crankshaft Onto Upper Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft thrust surface).
7. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
Fig 8: Pushing Crankshaft Rearward
Courtesy of FORD MOTOR CO.
Fig 9: Installing Rear Crankshaft Upper Thrust Washer
Courtesy of FORD MOTOR CO.
8. Install the rear (No. 5) main bearing cap.
9. 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.
10. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.
Fig 10: Pushing Crankshaft Forward To Seat Crankshaft Thrust Washer
Courtesy of FORD MOTOR CO.
11. Install the vertical main bearing cap fasteners and tighten in the sequence shown, in 4 stages.
    • Stage 1: Tighten fasteners 1 through 20 to 10 Nm (89 lb-in).
    • Stage 2: Tighten fasteners 1 through 10 to 25 Nm (18 lb-ft).
    • Stage 3: Tighten fasteners 11 through 20 to 40 Nm (30 lb-ft).
    • Stage 4: Tighten fasteners 1 through 20 an additional 90 degrees.
Fig 11: Installing Vertical Main Bearing Cap Fasteners
Courtesy of FORD MOTOR CO.
12. Install the cross-mounted main bearing cap fasteners and tighten in the sequence shown, in 2 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
Fig 12: Installing Cross-Mounted Main Bearing Cap Fasteners
Courtesy of FORD MOTOR CO.
13. Check the crankshaft end play. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
14. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
15. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
16. Assemble the pistons. For additional information, refer to Piston .
17. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
Fig 13: Identifying Piston Ring Gaps Positioning
Courtesy of FORD MOTOR CO.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only 1 connecting rod, rod bearing and piston is shown.
18. 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.
Fig 14: Using Special Tools To Install Piston And Connecting Rod Assembly
Courtesy of FORD MOTOR CO.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
19. Once the connecting rod is seated on the crankshaft journal, remove the special tools.
Fig 15: Identifying Special Tool (303-442)
Courtesy of FORD MOTOR CO.
CAUTION: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
20. Position the lower bearing and connecting rod and install the new bolts loosely.
NOTE: Main bearing caps are removed for clarity.
21. 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.
Fig 16: Identifying Connecting Rod Bearing Caps Tightening Sequence
Courtesy of FORD MOTOR CO.
22. Position the oil pump and install the 3 bolts.
    • Tighten to 10 N.m (89 lb-in).
Fig 17: Locating Oil Pump Bolts
Courtesy of FORD MOTOR CO.
23. Install the windage tray and the 7 nuts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 18: Locating Windage Tray And Nuts
Courtesy of FORD MOTOR CO.
CAUTION: Make sure the O-ring seal is in place and not damaged. A missing or damaged O-ring seal 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 seal. Lubricate the O-ring seal with clean engine oil prior to installation.
24. Install the spacer, oil pump screen and pickup tube and the 3 bolts.
    • Tighten the spacer and the oil pump screen and pickup tube-to-spacer bolt to 25 N.m (18 lb-ft).
    • Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 N.m (89 lb-in).
Fig 19: Identifying Spacer, Oil Pump Screen And Pickup Tube And Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in future oil leakage.
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.
25. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 cylinder head bolts loosely.
Fig 20: Positioning Cylinder Head Gaskets And Cylinder Heads Over Dowels
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
26. Tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
Fig 21: Tightening Bolts In Sequence
Courtesy of FORD MOTOR CO.
27. Remove the special tool from the LH cylinder head.
Fig 22: Identifying Special Tool (303-572) LH Cylinder Head
Courtesy of FORD MOTOR CO.
28. Remove the special tool from the RH cylinder head.
Fig 23: Identifying Special Tool (303-572) RH Cylinder Head
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
29. Install the hydraulic lash adjusters into the RH and LH cylinder heads.
Fig 24: Identifying Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
30. Install the LH and RH camshafts.
NOTE: LH shown, RH similar.
NOTE: Lubricate the camshaft bearing caps with clean engine oil.
31. Install the LH and RH camshaft bearing caps in their original locations.
    • 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.
Fig 25: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequence
Courtesy of FORD MOTOR CO.
CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE: LH shown, RH similar.
32. Position the camshaft phaser sprockets and install new camshaft phaser bolts finger tight.
Fig 26: Identifying Camshaft Phaser And Sprocket Assembly Bolt
Courtesy of FORD MOTOR CO.
CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
NOTE: LH shown, RH similar.
33. Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
Fig 27: Identifying Special Sprocket Phaser Tool
Courtesy of FORD MOTOR CO.
34. Install the crankshaft sprocket, making sure the flange faces forward.
Fig 28: Identifying Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
35. Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o'clock position.
Fig 29: Locating Crankshaft Sprocket Timing Mark
Courtesy of FORD MOTOR CO.
36. Rotate the camshaft sprockets to position the RH camshaft sprocket timing mark in the 11 o'clock position and the LH camshaft sprocket timing mark in the 12 o'clock position.
Fig 30: Rotating Camshaft Sprockets To Position RH Camshaft Sprocket Timing Mark
Courtesy of FORD MOTOR CO.
CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body, or permanent compression of the seal bead, will require replacement of the tensioner.
37. Inspect the RH and LH timing chain tensioners.
    • Install new tensioners as necessary.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
38. Compress the tensioner plunger, using a vise.
Fig 31: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
39. 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.
40. Remove the tensioner from the vise.
41. If the colored links are not visible, mark one link on one end and one link on the other end and use as timing marks.
Fig 33: Identifying Timing Chain Copper Links
Courtesy of FORD MOTOR CO.
42. Install the 4 bolts and the LH and RH timing chain guides.
    • Tighten to 10 N.m (89 lb-in).
Fig 34: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.
43. 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 colored (marked) link on the chain.
Fig 35: 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.
44. Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the colored (marked) chain link.
Fig 36: Locating Camshaft Sprocket Timing Copper Mark
Courtesy of FORD MOTOR CO.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
45. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 37: Identifying LH Timing Chain Tensioner & Tensioner Arm
Courtesy of FORD MOTOR CO.
46. Remove the retaining clip from the LH timing chain tensioner.
Fig 38: Identifying Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
47. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single colored (marked) chain link.
Fig 39: Aligning Crankshaft Sprocket Timing Mark And RH Timing Chain Link
Courtesy of FORD MOTOR CO.
NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.
NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
48. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the colored (marked) chain link.
Fig 40: Locating Camshaft Sprocket Timing Mark Aligned With Copper Chain Link
Courtesy of FORD MOTOR CO.
49. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 41: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
Courtesy of FORD MOTOR CO.
50. Remove the retaining clip from the RH timing chain tensioner.
Fig 42: Identifying Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
NOTE: The RH and LH camshaft phaser sprockets are similar. Refer to the single timing mark to identify the RH camshaft phaser sprocket and the L timing mark to identify the LH camshaft phaser sprocket.
51. As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note.
Fig 43: Verify Correct Alignment Of All Timing Marks
Courtesy of FORD MOTOR CO.
52. Install the crankshaft sensor ring on the crankshaft.
Fig 44: View Of Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the roller followers with clean engine oil prior to installation.
53. Using the special tool, install all of the camshaft roller followers.
Fig 45: 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. 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.
54. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
Fig 46: Applying Bead Of Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
55. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.
Fig 47: Installing Engine Front Cover Gasket
Courtesy of FORD MOTOR CO.
56. Tighten the 15 engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).

    Item	Part Number	Description
    1	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    2	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    3	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    4	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    5	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    6	W706508	Stud, Hex Shoulder Pilot, M8 x 1.25 x 50 - M6 x 1 x 10
    7	N808586	Stud and Washer, Hex Head Pilot, M8 x 1.25 - M6 x 1 x 86.35
    8	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    9	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    10	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    11	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    12	N806300	Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    13	N806300	Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    14	N806300	Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    15	N806300	Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1

Fig 48: Identifying Tightening Sequence Of Engine Front Cover Fasteners
Courtesy of FORD MOTOR CO.
57. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.
Fig 49: Locating Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
58. Using the special tools, install the crankshaft front oil seal into the engine front cover.
Fig 50: Installing Crankshaft Front Seal Using Special Tools (303-102, 303-335, 303-635)
Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.
59. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Fig 51: Applying Silicone Gasket And Sealant To Woodruff Key Slot In Crankshaft Pulley
Courtesy of FORD MOTOR CO.
60. Using the special tool, install the crankshaft pulley.
Fig 52: Installing Crankshaft Pulley Using Special Tool (303-102)
Courtesy of FORD MOTOR CO.
61. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the 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.
NOTE: Do not reuse the O-ring seals.
NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation.
62. Slide the coolant tube forward with the new O-ring seals into the cylinder block.
Fig 53: Sliding Coolant Tube Forward With O-Ring Seals Into Cylinder Block
Courtesy of FORD MOTOR CO.
63. Install the coolant tube stud bolt.
    • Tighten to 10 N.m (89 lb-in).
Fig 54: Locating Coolant Tube Stud Bolt
Courtesy of FORD MOTOR CO.
CAUTION: Do not rotate the coolant pump housing once the coolant pump housing has been positioned in the cylinder block. Damage to the O-ring seal will occur.
NOTE: Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
64. Position the coolant pump and install the 4 bolts loosely.
Fig 55: Identifying Coolant Pump
Courtesy of FORD MOTOR CO.
65. Tighten the 4 coolant pump bolts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 56: Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
66. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 57: Identifying Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
67. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 58: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts
Courtesy of FORD MOTOR CO.
68. Install 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.
NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
69. Install the LH camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
Fig 60: Locating Camshaft Position (CMP) Sensor And Bolt
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
70. Install the RH CMP sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
Fig 61: Locating RH CMP Sensor And Bolt
Courtesy of FORD MOTOR CO.
71. Install the knock sensor (KS) and the bolts.
    • Tighten to 20 N.m (15 lb-ft).
Fig 62: Locating Knock Sensor (KS) And 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.
72. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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. Failure to follow this procedure can cause future oil leakage.
73. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Fig 63: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
Courtesy of FORD MOTOR CO.
CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
74. Position the RH valve cover and gasket on the cylinder head and tighten the 14 bolts in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
Fig 64: Identifying Tightening Sequence Of Valve Cover 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.
75. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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. Failure to follow this procedure can cause future oil leakage.
76. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Fig 65: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
Courtesy of FORD MOTOR CO.
CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
77. Position the LH valve cover and gasket on the cylinder head and tighten the 15 bolts in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
Fig 66: Identifying Tighten Sequence Of Valve Cover Bolts
Courtesy of FORD MOTOR CO.
78. Install 8 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
79. 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 67: Tightening RH Exhaust Manifold Bolts In Sequence
Courtesy of FORD MOTOR CO.
80. Install the RH motor mount bracket, 2 bolts and 2 stud bolts.
    • Tighten to 55 Nm (41 lb-ft).
Fig 68: Locating Motor Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
81. Install the oil level indicator tube and the bolt.
    • Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
    • Tighten to 10 N.m (89 lb-in).
Fig 69: Locating Oil Level Indicator Tube Bolt
Courtesy of FORD MOTOR CO.
82. Install 8 new LH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
83. 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 70: Tightening LH Exhaust Manifold Nuts In Sequence
Courtesy of FORD MOTOR CO.
84. Install the LH motor mount bracket and 4 bolts.
    • Tighten to 55 Nm (41 lb-ft).
Fig 71: Locating Motor Mount Bracket And Bolts
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: Clean and inspect the mating surfaces and install new gaskets.
85. Position the oil filter adapter and install the 4 bolts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 72: Locating Oil Filter Adapter And Bolts
Courtesy of FORD MOTOR CO.
86. Install a new oil filter.
NOTE: LH shown, RH similar.
87. Install the 8 ignition coils and the 8 bolts.
    • Tighten to 6 N.m (53 lb-in).
Fig 73: Identifying Ignition Coils And Bolts
Courtesy of FORD MOTOR CO.
88. Install the ground strap and nut to the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 74: Locating Ground Strap And Nut On Stud Bolt
Courtesy of FORD MOTOR CO.
89. Position the engine wiring harness on the engine.
90. Connect the engine oil pressure (EOP) switch electrical connector.
Fig 75: Locating Engine Oil Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
91. Attach the engine wiring harness retainer to the stud bolt.
    • Connect the LH heated oxygen sensor (HO2S) electrical connector.
Fig 76: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
92. Connect the KS electrical connector and pin-type retainer.
Fig 77: Locating Knock Sensor (KS) Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
93. Attach the CHT sensor jumper harness electrical connector pin-type retainer.
Fig 78: Identifying Cylinder Head Temperature (CHT) Sensor Jumper Harness Electrical Connector
Courtesy of FORD MOTOR CO.
94. Connect the CHT sensor electrical connector.
Fig 79: Locating CHT Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
95. Detach the engine wiring harness pin-type retainers.
Fig 80: Locating Engine Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
96. Connect the 2 engine wiring harness retainers to the LH valve cover studs.
Fig 81: Locating Engine Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
97. Connect the 2 engine wiring harness retainers to the RH valve cover studs.
Fig 82: Locating Engine Wiring Harness Retainers At RH Valve Cover
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
98. Connect the 4 RH and 4 LH ignition coil electrical connectors.
Fig 83: Locating Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
99. Connect the PCV tubes from the RH and LH valve covers.
Fig 84: Locating Positive Crankcase Ventilation Tubes
Courtesy of FORD MOTOR CO.
100. Install the RH radio ignition interference capacitor and nut.
     • Tighten to 25 Nm (18 lb-ft).
Fig 85: Identifying Nut & RH Radio Ignition Interference Capacitor
Courtesy of FORD MOTOR CO.
101. Attach the engine wiring harness pin-type retainers.
Fig 86: Locating Engine Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
102. Connect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.
Fig 87: Locating Camshaft Timing (VCT) Solenoid Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
103. Connect the RH and LH camshaft position (CMP) sensor electrical connectors.
Fig 88: Identifying RH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
104. Install the special tool.
Fig 89: Identifying Special Tool (303-F047)
Courtesy of FORD MOTOR CO.
105. Using a suitable floor crane, remove the engine from the engine stand.
NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker must be applied to the rear crankshaft seal retainer mating surface on the engine block.
106. Apply a bead of gasket maker to the rear crankshaft seal retainer mating surface on the engine block.
Fig 90: Applying Bead Of Gasket Maker To Rear Crankshaft Seal Retainer
Courtesy of FORD MOTOR CO.
107. 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.
108. Tighten the 6 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.
109. 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.
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. Failure to follow this procedure can cause future oil leakage.
110. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
Fig 93: Applying Silicone Gasket And Sealant
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. Failure to follow this procedure can cause future oil leakage.
111. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
Fig 94: Applying Silicone Gasket & Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
112. Install the new oil pan gasket and the oil pan and loosely install the 16 bolts.
Fig 95: Positioning New Oil Pan Gasket And Oil Pan
Courtesy of FORD MOTOR CO.
113. Tighten the 16 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.
114. Using the special tools, install a new crankshaft rear seal.
Fig 97: Using Special Tools To Install New Crankshaft Rear Seal
Courtesy of FORD MOTOR CO.
115. Using the special tools, install a new crankshaft rear oil slinger.
Fig 98: Installing Crankshaft Rear Oil Slinger Using Special Tools (303-516, 303-517, 303-518)
Courtesy of FORD MOTOR CO.

Vehicles with automatic transmission 

116. Install the flexplate and the 6 bolts in the sequence shown.
     • Tighten to 80 N.m (59 lb-ft).
Fig 99: Identifying Flexplate Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.

Vehicles with manual transmission 

117. Position the flywheel on the crankshaft pilot and start the 6 flywheel bolts.
118. Tighten the flywheel bolts evenly in the sequence shown to fully seat the flywheel on the crankshaft pilot.
     • Tighten to 80 Nm (59 lb-ft).
Fig 100: Removing Bolts & Flywheel In Sequence
Courtesy of FORD MOTOR CO.