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Section 796 (Engine - 6.8L (3V) -- F250-F550 Super Duty): Assembly: Engine: Assembly

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Record the main bearing code found on the front of the engine block.
    Fig 1: Identifying Main Bearing Code Found On Front Of Engine Block
    G04583819Courtesy of FORD MOTOR CO.
  2. Record the main bearing code found on the back of the crankshaft.
    Fig 2: Identifying Main Bearing Code - Found On Back Of Crankshaft
    G03886015Courtesy of FORD MOTOR CO.
  3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
    • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
    • Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the 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 3: Bearing Select Fit Chart (Standard Bearings)
    G03886016Courtesy of FORD MOTOR CO.
  4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
    Fig 4: Bearing Select Fit Chart (Oversize Bearings)
    G04583822Courtesy of FORD MOTOR CO.
    5. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
  5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
    6. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
    Fig 5: Installing Crankshaft Upper Main Bearings
    GF0005637Courtesy of FORD MOTOR CO.
  6. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
  7. Install the crankshaft into the cylinder block and onto the upper crankshaft main bearings.
    Fig 6: Installing Crankshaft Into Cylinder Block And Upper Crankshaft Main Bearings
    GF0005638Courtesy of FORD MOTOR CO.
    8. NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
    Fig 7: Installing Rear Crankshaft Upper Thrust Washer
    GF0000612Courtesy of FORD MOTOR CO.
  8. Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.
    9. NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
    Fig 8: Identifying Front Upper Crankshaft Thrust Washer
    G03886020Courtesy of FORD MOTOR CO.
  9. Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.
    10. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
    NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
    Fig 9: Installing Lower Crankshaft Thrust Washer To Back Side Of No 6 Main Bearing Cap
    GF0005639Courtesy of FORD MOTOR CO.
  10. Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.
  11. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
  12. Install the bolts.
    Fig 10: Installing No. 1 Through No. 5 Crankshaft Lower Main Bearings Bolts
    GF0005640Courtesy of FORD MOTOR CO.
  13. Install the 10 dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.
    Fig 11: Installing Dowel Pins
    GF0005641Courtesy of FORD MOTOR CO.
  14. Tighten fasteners 1 through 12 in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 12: Identifying Fasteners Tightening Sequence (1-12)
    GF0005642Courtesy of FORD MOTOR CO.
  15. Tighten fasteners 13 through 24 in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 30 N.m (22 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 13: Identifying Fasteners Tightening Sequence (13-24)
    GF0005643Courtesy of FORD MOTOR CO.
  16. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  17. Assemble the 10 pistons. For additional information, refer to Piston  in this article.
  18. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
    Fig 14: Identifying Piston Ring Gap Positioning
    G03920387Courtesy of FORD MOTOR CO.
  19. Using the special tools, install the piston and connecting rod assembly.
    Fig 15: Installing Piston And Connecting Rod Assembly
    GF0005644Courtesy of FORD MOTOR CO.
    20. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 16: Identifying Special Tool
    G03920389Courtesy of FORD MOTOR CO.
  20. Once the connecting rod is seated on the crankshaft journal, remove the special tools.
    21. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.
    NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
  21. Install the connecting rod bearings, position the connecting rod cap and loosely install the 2 new bolts.
    22. NOTE: Be sure to tighten the bolts in 2 stages.
    Fig 17: Tightening Connecting Rod Bolts In Sequence
    GF0005645Courtesy of FORD MOTOR CO.
  22. Tighten the connecting rod bolts in the sequence shown.
    • Stage 1: Tighten to 43 N.m (32 lb-ft).
    • Stage 2: Tighten an additional 105 degrees.
  23. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.
  24. Position the oil pump and install the bolts.
    • Tighten to 10 N.m (89 lb-in).
    Fig 18: Locating Oil Pump Bolts
    G04638972Courtesy of FORD MOTOR CO.
  25. Install the oil pump screen and pickup tube spacer.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 19: Installing Oil Pump Screen And Pickup Tube Spacer
    GF0002808Courtesy of FORD MOTOR CO.
    26. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
    NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil prior to installation.
    Fig 20: Positioning Oil Pump Screen, Pickup Tube And Installing Bolts
    GF0002809Courtesy of FORD MOTOR CO.
  26. Position the oil pump screen and pickup tube and install the bolts.
    • Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 N.m (89 lb-in).
    • Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 N.m (18 lb-ft).
  27. Rotate the crankshaft to position the keyway at 12 o'clock.
    Fig 21: Rotating Crankshaft To Position Keyway At 12 O'Clock
    GF0005646Courtesy of FORD MOTOR CO.
    28. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    NOTE: Do not turn the crankshaft until instructed to do so.
    NOTE: LH shown, RH similar.
    Fig 22: Identifying Special Tools
    GF0005647Courtesy of FORD MOTOR CO.
  28. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
    29. NOTE: Be sure to tighten the bolts in 3 stages.
    Fig 23: Tightening Cylinder Head Bolts In Sequence
    GF0005648Courtesy of FORD MOTOR CO.
  29. Tighten the bolts 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.
  30. Remove the special tool from the LH cylinder head.
    Fig 24: Identifying Special Tool Onto Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  31. Remove the special tool from the RH cylinder head.
    Fig 25: Identifying Special Tool On Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
  32. Install the hydraulic lash adjusters into the RH and LH cylinder heads.
    • Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
    Fig 26: Identifying Hydraulic Lash Adjusters
    G03920399Courtesy of FORD MOTOR CO.
    33. CAUTION: If the components are to be reinstalled, they must be installed into their original locations.
    NOTE: Camshaft shown installed to clarify camshaft roller follower position.
    NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.
    Fig 27: Installing Identified Camshaft Roller Followers Onto RH Cylinder Head
    GF0005583Courtesy of FORD MOTOR CO.
  33. Install only the identified camshaft roller followers onto the RH cylinder head.
    34. CAUTION: If the components are to be reinstalled, they must be installed into their original locations.
    NOTE: Camshaft shown installed to clarify camshaft roller follower position.
    NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.
    Fig 28: Installing Identified Camshaft Roller Followers Onto LH Cylinder Head
    GF0005584Courtesy of FORD MOTOR CO.
  34. Install only the identified camshaft roller followers onto the LH cylinder head.
  35. Install the LH and RH camshafts.
    • Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
  36. Install the LH and RH camshaft bearing caps in their original locations.
    • Lubricate the camshaft bearing caps with clean engine oil.
    • Position the front camshaft bearing cap.
    • Position the remaining camshaft bearing caps.
    • Install the bolts loosely.
  37. Tighten the LH camshaft bearing cap bolts in 2 stages:
    • Stage 1: Tighten to 8 N.m (71 lb-in) in the sequence shown.
    • Stage 2: Tighten an additional 45 degrees.
    Fig 29: Identifying LH Camshaft Bearing Cap Bolt Removal/Installation Sequence
    G03920678Courtesy of FORD MOTOR CO.
  38. Tighten the RH camshaft bearing cap bolts in 2 stages:
    • Stage 1: Tighten to 8 N.m (71 lb-in) in the sequence shown.
    • Stage 2: Tighten an additional 45 degrees.
    Fig 30: Identifying RH Camshaft Bearing Cap Bolt Removal/Installation Sequence
    G03920676Courtesy of FORD MOTOR CO.
  39. Install the balance shaft drive gear onto the LH camshaft.
  40. Install both camshaft sprockets and camshaft sprocket bolts finger tight.
    41. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
    Fig 31: Compressing Tensioner Plunger
    G03885344Courtesy of FORD MOTOR CO.
  41. Compress the tensioner plunger, using a vise.
  42. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 32: Identifying Retaining Clip on Tensioner
    G03881580Courtesy of FORD MOTOR CO.
    43. NOTE: There are 61 links in each timing chain.
    Fig 33: Locating Timing Chain Marks
    G03885317Courtesy of FORD MOTOR CO.
  43. If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
  44. Install the timing chain guides and the 4 bolts.
    • Tighten to 10 N.m (89 lb-in).
    Fig 34: Locating Timing Chain Guides Bolts
    G03920972Courtesy of FORD MOTOR CO.
  45. Using the special tool, position the cranskshaft then remove the tool.
    Fig 35: Positioning Crankshaft With Special Tool
    G03919963Courtesy of FORD MOTOR CO.
  46. Preposition the camshafts.
    • Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.
    • Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
      Fig 36: Identifying LH And RH Camshaft Timing Mark Position
      G04583473Courtesy of FORD MOTOR CO.
  47. Install the crankshaft sprocket, marking sure the flange faces forward.
    Fig 37: Identifying Crankshaft Sprocket
    G03919967Courtesy of FORD MOTOR CO.
  48. Install the lower end of the LH timing chain, aligning the timing marks.
    Fig 38: Aligning Timing Mark Of Crankshaft Sprocket With Single Copper Link On Chain
    G03886474Courtesy of FORD MOTOR CO.
    49. NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.
    Fig 39: Aligning Timing Marks On Sprocket With Marked Chain Links
    G03906562Courtesy of FORD MOTOR CO.
  49. Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
    50. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 40: Identifying LH Timing Chain Tensioner And Tensioner Arm
    G03919950Courtesy of FORD MOTOR CO.
  50. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
    51. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.
    NOTE: The lower half of the timing chain must be positioned above the dowel.
    Fig 41: Aligning Timing Mark On Crankshaft Sprocket With Single Copper Chain Link
    G03885327Courtesy of FORD MOTOR CO.
  51. Install the RH (outer) timing chain on the crankshaft sprocket.
  52. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
    Fig 42: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark
    G03885328Courtesy of FORD MOTOR CO.
  53. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 43: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
    G03919951Courtesy of FORD MOTOR CO.
  54. Remove the retaining clips from the RH and LH timing chain tensioners.
    Fig 44: View Of Retaining Clip And Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  55. Check for correct alignment of all timing marks.
    Fig 45: Identifying Alignment Of All Timing Marks
    G03906021Courtesy of FORD MOTOR CO.
  56. Install the crankshaft sensor ring on the crankshaft.
    Fig 46: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    57. CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
    Fig 47: Identifying Camshaft Sprocket Bolt
    G03920660Courtesy of FORD MOTOR CO.
  57. Tighten the RH camshaft sprocket bolt in 2 stages:
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    58. CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
    Fig 48: Identifying LH Camshaft Sprocket Bolt
    G03920661Courtesy of FORD MOTOR CO.
  58. Tighten the LH camshaft sprocket bolt in 2 stages:
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  59. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    Fig 49: Crankshaft Positioned With Keyway At 6 O'clock Position
    G03919949Courtesy of FORD MOTOR CO.
  60. Remove the 2 bolts and the camshaft bearing cap.
    Fig 50: Identifying Bolts And Camshaft Bearing Cap
    G03920703Courtesy of FORD MOTOR CO.
    61. CAUTION: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
    Fig 51: Identifying Special Tool Into Roller Follower
    GF0005585Courtesy of FORD MOTOR CO.
  61. Using the special tool, install the roller follower.
    • Lubricate the camshaft roller follower with clean engine oil prior to installation.
  62. Position the camshaft bearing cap and install the bolts in 2 stages:
    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
    Fig 52: Identifying Bolts And Camshaft Bearing Cap
    G03920703Courtesy of FORD MOTOR CO.
  63. Remove the 2 bolts and the camshaft bearing cap.
    Fig 53: Identifying Bolts And Camshaft Bearing Cap
    G03920706Courtesy of FORD MOTOR CO.
    64. CAUTION: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
    Fig 54: Installing Roller Follower
    GF0005586Courtesy of FORD MOTOR CO.
  64. Using the special tool, install the roller follower.
    • Lubricate the camshaft roller follower with clean engine oil prior to installation.
  65. Position the camshaft bearing cap and install the bolts in 2 stages:
    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
    Fig 55: Identifying Bolts And Camshaft Bearing Cap
    G03920706Courtesy of FORD MOTOR CO.
    66. CAUTION: If the components are to be reinstalled, they must be installed into their original locations.
    Fig 56: Compressing Spring Using Special Tool
    G03919948Courtesy of FORD MOTOR CO.
  66. Using the special tool, install all of the remaining camshaft roller followers.
    • Lubricate the camshaft roller followers with clean engine oil prior to installation.
  67. Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
  68. Lubricate the balance shaft journals with clean engine oil.
  69. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
  70. Position the balance shaft on the journals.
    Fig 57: Identifying Balance Shaft And Gear Tooth Marks
    G03886484Courtesy of FORD MOTOR CO.
    71. NOTE: It may be necessary to use an inspection mirror to see the marks.
    Fig 58: Aligning Mark On Balance Shaft With Camshaft Timing Mark
    G03886486Courtesy of FORD MOTOR CO.
  71. Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.
    72. NOTE: Install the balance shaft bearing caps in their original locations.
    Fig 59: Identifying Balance Shaft Bolt Loosening/Tightening Sequence
    G03920712Courtesy of FORD MOTOR CO.
  72. Install the bolts and tighten in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
    73. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
    Fig 60: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
    GF0005649Courtesy of FORD MOTOR CO.
  73. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
  74. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
    Fig 61: Installing Engine Front Cover Gasket
    GF0000367Courtesy of FORD MOTOR CO.
  75. Tighten the engine front cover fasteners in sequence in 2 stages.

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

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

    Fig 62: Tightening Front Cover Fasteners In Sequence
    GF0005575Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
    6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    11 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    15 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 56
    76. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
    Fig 63: Locating Camshaft (CMP) Sensor Bolt
    G03920013Courtesy of FORD MOTOR CO.
  76. Install the camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
    77. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
    Fig 64: Identifying Coolant Pump
    G03885759Courtesy of FORD MOTOR CO.
  77. Position the coolant pump and install the bolts loosely.
    • Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
  78. Tighten the 4 coolant pump bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 65: Identifying Coolant Pump Bolts
    GF0000354Courtesy of FORD MOTOR CO.
  79. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
    Fig 66: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  80. Using the special tools, install the crankshaft seal into the engine front cover.
    Fig 67: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    81. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 68: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  81. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  82. Use the special tool to install the crankshaft pulley.
    Fig 69: Using Special Tool To Install Crankshaft Pulley
    G03920552Courtesy of FORD MOTOR CO.
  83. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 70: Tightening Crankshaft Pulley Bolt
    GF0002723Courtesy of FORD MOTOR CO.
  84. Position the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 71: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
  85. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 72: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
  86. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 73: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt
    G03920233Courtesy of FORD MOTOR CO.
    87. NOTE: LH shown, RH similar.
    Fig 74: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
  87. Install the cylinder block drain plugs.
    • Tighten to 24 Nm (18 lb-ft).
    88. 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 a new gasket.
    Fig 75: Positioning Oil Filter Adapter Bolts And Nut
    GF0005556Courtesy of FORD MOTOR CO.
  88. Position the oil filter adapter and install the 4 bolts and the nut.
    • Tighten to 25 N.m (18 lb-ft).
  89. Position a new gasket, the LH exhaust manifold and tighten the 10 nuts in the sequence shown.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 76: Identifying Tightening Sequence For LH Exhaust Manifold Bolts
    GF0005596Courtesy of FORD MOTOR CO.
  90. Install the LH engine support insulator and the 4 bolts.
    • Tighten to 63 N.m (46 lb-ft).
    Fig 77: Installing LH Engine Support Insulator Bolts
    GF0005607Courtesy of FORD MOTOR CO.
  91. Position a new gasket, the RH exhaust manifold and tighten the 10 nuts in the sequence shown.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 78: Identifying RH Exhaust Manifold Nuts Tightening Sequence
    GF0005593Courtesy of FORD MOTOR CO.
  92. Install the RH engine support insulator and the 4 bolts.
    • Tighten to 63 N.m (46 lb-ft).
    Fig 79: Locating RH Engine Mount Bolts
    G04647883Courtesy of FORD MOTOR CO.
    93. 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.
  93. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    94. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 80: Identifying Silicone Gasket And Sealant Application Points
    GF0005568Courtesy of FORD MOTOR CO.
  94. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
  95. Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
    Fig 81: Identifying Valve Cover Fasteners Loosening/Tightening Sequence
    G03920595Courtesy of FORD MOTOR CO.
    96. 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.
  96. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    97. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 82: Identifying Silicone Gasket And Sealant Application Points
    GF0005565Courtesy of FORD MOTOR CO.
  97. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
  98. Position the LH valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
    Fig 83: Identifying Valve Cover Fasteners Tightening Sequence
    G03920580Courtesy of FORD MOTOR CO.
    99. NOTE: Do not reuse the O-ring seals.
    NOTE: Lubricate the new O-ring seals with clean engine coolant prior to installation.
    Fig 84: Sliding Coolant Tube Forward With O-Ring Seals Into Cylinder Block
    GF0000368Courtesy of FORD MOTOR CO.
  99. Slide the coolant tube forward with the new O-ring seals into the cylinder block.
  100. Install the coolant tube stud bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 85: Identifying Coolant Tube Stud Bolt
    G03920263Courtesy of FORD MOTOR CO.
  101. Install the 2 knock sensors (KS) and the bolts.
    • Tighten to 20 N.m (15 lb-ft).
    Fig 86: Identifying Knock Sensors (KS)
    G03920293Courtesy of FORD MOTOR CO.
  102. Install the oil level indicator tube and the front bolt.
    • Tighten to 25 N.m (18 lb-ft).
    • Install a new O-ring seal and lubricate with clean engine oil prior to installation.
    Fig 87: Locating Front Oil Level Indicator Tube Bolt
    G03920296Courtesy of FORD MOTOR CO.
  103. Install the rear oil level indicator tube bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 88: Locating Rear Oil Level Indicator Tube Bolt
    G03920295Courtesy of FORD MOTOR CO.
  104. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
  105. Connect the CKP sensor electrical connector.
    Fig 89: Connecting CKP Sensor Electrical Connector
    GF0002667Courtesy of FORD MOTOR CO.
  106. Install the 10 ignition coils and the 10 bolts.
    • Tighten to 6 N.m (53 lb-in).
    Fig 90: Locating Ignition Coils Bolts
    GF0005614Courtesy of FORD MOTOR CO.
  107. Connect the 10 ignition coil electrical connectors.
    Fig 91: Locating Ignition Coil Electrical Connectors
    GF0005613Courtesy of FORD MOTOR CO.
  108. Install the LH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 92: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
    G03920225Courtesy of FORD MOTOR CO.
  109. Connect the engine oil pressure (EOP) sensor electrical connector.
    Fig 93: Identifying Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03919846Courtesy of FORD MOTOR CO.
  110. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 94: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  111. Connect the electrical connector retainer to the coolant tube.
    Fig 95: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  112. Install the RH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 96: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
    G03920219Courtesy of FORD MOTOR CO.
  113. Connect the CMP sensor electrical connector.
    Fig 97: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  114. Connect the lower radiator hose to the oil filter adapter.
    Fig 98: Connecting Lower Radiator Hose To Oil Filter Adapter
    GF0005555Courtesy of FORD MOTOR CO.
  115. Using a suitable floor crane, remove the engine from the engine stand.
  116. Lower and support the engine assembly on wood blocks.
  117. Install the special tool.
    Fig 99: Identifying Special Tool
    G03920205Courtesy of FORD MOTOR CO.
  118. Using a suitable floor crane raise the engine.
    119. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  119. Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    120. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 100: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
    GF0002781Courtesy of FORD MOTOR CO.
  120. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
  121. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
    Fig 101: Locating Crankshaft Rear Seal Retainer Plate Bolts
    GF0000369Courtesy of FORD MOTOR CO.
  122. Tighten the bolts in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
    Fig 102: Identifying Bolt Tightening Sequence
    GF0002812Courtesy of FORD MOTOR CO.
    123. 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.
  123. 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.
    124. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 103: Applying Silicone Gasket And Sealant
    GF0000322Courtesy of FORD MOTOR CO.
  124. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
    125. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 104: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Mating Surface
    G03920465Courtesy of FORD MOTOR CO.
  125. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
  126. Install the oil pan gasket and the oil pan and loosely install the 18 bolts.
  127. Tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 2 N.m (18 lb-in).
    • Stage 2: Tighten to 20 N.m (15 lb-ft).
    • Stage 3: Tighten an additional 60 degrees.
    Fig 105: Identifying Tightening Sequence For Oil Pan Bolts
    GF0005603Courtesy of FORD MOTOR CO.
    128. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
    Fig 106: Using Special Tools To Install New Crankshaft Rear Seal
    G04583928Courtesy of FORD MOTOR CO.
  128. Using the special tools, install a new crankshaft rear seal.
  129. Using the special tools, install a new crankshaft rear oil slinger.
    Fig 107: Installing Crankshaft Rear Oil Slinger Using Special Tools
    G03920154Courtesy of FORD MOTOR CO.
  130. Install the flexplate or flywheel and the 8 bolts in the sequence shown.
    • Tighten to 80 N.m (59 lb-ft).
    Fig 108: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts
    G03920141Courtesy of FORD MOTOR CO.
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