Cylinder Heads and Intake Manifolds

Fig 1: Exploded View Of Cylinder Heads And Intake Manifolds Components

Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: This procedure is for selecting bearings using a new crankshaft.
1. Select the crankshaft main bearings for each crankshaft journal.
   1. Read the code on the crankshaft flange.
   2. Read the code on the cylinder block rear face.
      • The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for main No. 2.
      • The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2 numbers for main No. 4.
        Fig 2: Identifying Codes On Crankshaft Flange And Cylinder Block Rear Face

        Courtesy of FORD MOTOR CO.
2. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
   • For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
     Fig 3: View Of Block And Crankshaft Codes Chart

     Courtesy of FORD MOTOR CO.
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
Fig 4: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
3. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
4. Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the lower cylinder block.
   Fig 5: Locating Bearings On Lower Cylinder Block

   Courtesy of FORD MOTOR CO.
5. Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.
   Fig 6: Locating Crankshaft Thrust Bearing

   Courtesy of FORD MOTOR CO.
6. Install the crankshaft key.
   Fig 7: Locating Crankshaft Key

   Courtesy of FORD MOTOR CO.
7. Apply clean engine oil to the crankshaft main and rod bearing journals.
8. Position the crankshaft in the cylinder block.
   Fig 8: Locating Crankshaft Position In Cylinder Block

   Courtesy of FORD MOTOR CO.
NOTE: The lower cylinder block must be installed and the bolts tightened within 4 minutes of applying the sealant.
NOTE: Clean and degrease both surfaces using metal surface prep before applying sealant.
Fig 9: Identifying Gasket And Sealant Applying Area Of Cylinder Block
Courtesy of FORD MOTOR CO.
9. Apply gasket and sealant to the cylinder block as shown in illustration.
NOTE: Fasteners No. 5 through 8 are studs. Fasteners No. 18 through 22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 1 through 4, 17 are M8 x 1.25 mm x 96 mm (0.05 in x 3.75 in) bolts. Fasteners 9 through 12 are M10 x 1.5 mm x 106.8 mm (0.06 in x 4.20 in) /M8 x 1.25 mm x 21.5 mm (0.05 in x 0.84 in) studs. Fasteners 13 through 16 are M10 x 1.5 mm x 106.5 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position or engine damage can result.
10. Position the lower cylinder block and install the new bolts and new studs.
    • Tighten the bolts and studs in the sequence shown in 4 stages.
    • Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft).
    • Stage 2: Tighten fasteners 9 through 16 to 40 Nm (30 lb-ft).
    • Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees.
    • Stage 4: Tighten fasteners 17 through 22 to 25 Nm (18 lb-ft).
      Fig 10: Identifying Lower Cylinder Block Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
11. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
    • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge with Holding Fixture.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • Acceptable crankshaft end play is 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
      Fig 11: Measuring Crankshaft End Play Using Dial Indicator Gauge With Holding Fixture

      Courtesy of FORD MOTOR CO.
12. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal.
    Fig 12: Installing Crankshaft Rear Main Oil Seal Using Special Tools

    Courtesy of FORD MOTOR CO.
13. Install the engine-to-transaxle separator plate.
    Fig 13: Locating Engine-To-Transaxle Separator Plate

    Courtesy of FORD MOTOR CO.
14. Position the flexplate and install the bolts.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 14: Locating Flexplate Bolts

      Courtesy of FORD MOTOR CO.
15. Mount the engine on an engine stand.
16. Using the chart, select the correct piston grade size for the cylinder bores.
    • Measure the cylinder block bore diameter.
    • Mark the outside of the block with the appropriate number(s) to identify bore grade size.
    • Choose the correct piston grade size for the cylinder bore.
      Fig 15: View Of Piston Grade Size Chart For Cylinder Bore

      Courtesy of FORD MOTOR CO.
NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES - PISTON  in this service information.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
NOTE: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.
Fig 16: Installing Piston And Connecting Rod Assemblies
Courtesy of FORD MOTOR CO.
17. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
18. Install the connecting rod caps and the new bolts.
    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
      Fig 17: Connecting Rod Cap Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
19. Install the crankcase cover, a new gasket and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 18: Locating Oil Separator Cover Bolts

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
20. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence in illustration in 6 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten to 90 Nm (66 lb-ft).
    • Stage 3: Loosen one full turn.
    • Stage 4: Tighten to 40 Nm (30 lb-ft).
    • Stage 5: Tighten 90 degrees.
    • Stage 6: Tighten 90 degrees.
      Fig 19: Identifying Cylinder Heads Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
21. Install the crankshaft pulley bolt and rotate the crankshaft keyway to the 11 o'clock position to locate Top Dead Center (TDC).
    Fig 20: Locating Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
NOTE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
22. Install the hydraulic lash adjusters.
    • Lubricate the hydraulic lash adjusters with clean engine oil.
23. Apply clean engine oil to the LH and RH camshaft roller followers.
NOTE: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE: RH shown in illustration, LH similar.
Fig 21: Locating Roller Follower
Courtesy of FORD MOTOR CO.
24. Install the LH and RH camshaft roller followers.
NOTE: LH shown in illustration, RH similar.
Fig 22: Locating Oil Filter Screen
Courtesy of FORD MOTOR CO.
25. Install the new LH and RH oil filter screens in the intake camshafts.
26. Position the camshaft phaser and sprockets onto the intake camshafts.
    • Install the 3 bolts finger-tight.
27. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
    • Align the LH camshafts as shown in illustration.
      Fig 23: Identifying LH Camshafts Are In The Neutral Position

      Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
28. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
    • Loosely install the bolts.
      Fig 24: Locating LH Camshaft Bearing Caps Bolts

      Courtesy of FORD MOTOR CO.
29. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
    • Loosely install the bolts.
      Fig 25: Locating Bearing Thrust Cap Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
30. Tighten the LH camshaft bearing cap bolts in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
      Fig 26: Camshaft Bearing Cap Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
Fig 27: Remove/Install LH Camshaft Phaser And Sprocket Bolt
Courtesy of FORD MOTOR CO.
31. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
32. Install the camshaft oil seal retainer and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Locating Camshaft Oil Seal Retainer With Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
Fig 29: Installing Camshaft Oil Seal Using Special Tools
Courtesy of FORD MOTOR CO.
33. Using the Power Steering Pump Pulley Installer, Camshaft Oil Seal Installer and the Camshaft Oil Seal Protector, install a new camshaft oil seal.
34. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
    • Align the RH camshafts as shown in illustration.
      Fig 30: Identifying RH Camshafts Positions

      Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed or damage to the thrust caps can occur.
NOTE: Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil.
35. Install the camshaft bearing caps.
    • Loosely install the bolts.
      Fig 31: Locating Camshaft Bearing Cap Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil.
36. Install the camshaft bearing thrust caps.
    • Loosely install the bolts.
      Fig 32: Locating Camshaft Bearing Thrust Caps

      Courtesy of FORD MOTOR CO.
NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
37. Tighten the RH camshaft bearing cap bolts in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
      Fig 33: Identifying RH Camshaft Bearing Cap Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
Fig 34: Remove/Install RH Camshaft Phaser And Sprocket Bolt
Courtesy of FORD MOTOR CO.
38. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
39. Position the oil pump and install the bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 35: Identifying Oil Pump Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
40. Remove the crankshaft pulley bolt.
    Fig 36: Locating Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Failure to verify correct timing drive component alignment will result in severe engine damage.
Fig 37: Locating Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
41. Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH timing chains will be aligned to this mark during assembly.
NOTE: LH shown in illustration, RH similar.
Fig 38: Positioning Chain Tensioner In A Soft-Jawed Vise
Courtesy of FORD MOTOR CO.
42. Position the chain tensioner in a soft-jawed vise.
NOTE: LH shown in illustration, RH similar.
Fig 39: Holding Chain Tensioner Ratchet Lock Mechanism With A Small Pick
Courtesy of FORD MOTOR CO.
43. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
NOTE: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
44. Slowly compress the timing chain tensioner.
45. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
    Fig 40: Holding Tensioner Piston With A 1.5 mm (0.06 In) Diameter Wire Or Paper Clip

    Courtesy of FORD MOTOR CO.
46. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
    1. Mark any link to use as the crankshaft timing mark.
    2. Starting with the crankshaft timing mark, count 29 links and mark the link.
    3. Continue counting to link 42 and mark the link.
       Fig 41: Identifying Timing Marks On LH And RH Timing Chains

       Courtesy of FORD MOTOR CO.
47. Position the LH timing chain and guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
      Fig 42: Locating LH Timing Chain Guide With Bolts

      Courtesy of FORD MOTOR CO.
48. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
       • Tighten to 25 Nm (18 lb-ft).
         Fig 43: Identifying LH Timing Chain Tensioner Arm And Bolts

         Courtesy of FORD MOTOR CO.
49. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
    Fig 44: Locating Crankshaft Keyway

    Courtesy of FORD MOTOR CO.
50. Verify that the RH camshafts are correctly positioned.
    Fig 45: Identifying RH Camshafts Positions

    Courtesy of FORD MOTOR CO.
51. Install the RH timing chain and chain guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
      Fig 46: Locating RH Timing Chain Guide And Bolts

      Courtesy of FORD MOTOR CO.
52. Install the RH timing chain tensioner and tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
       • Tighten to 25 Nm (18 lb-ft).
         Fig 47: Identifying RH Timing Chain Tensioner, Tensioner Arm With Bolts

         Courtesy of FORD MOTOR CO.
53. Remove the LH and RH timing chain tensioner piston retaining wires.
54. Rotate the crankshaft counterclockwise 120 degrees to TDC.
NOTE: Failure to verify correct timing drive component alignment will result in severe engine damage.
55. Verify the timing with the following steps.
    1. There should be 12 chain links between the camshaft timing marks.
    2. There should be 27 chain links between the camshaft and the crankshaft timing marks.
    3. There should be 30 chain links between the camshaft and the crankshaft timing marks.
       Fig 48: Locating Chain Links Between Camshaft And Crankshaft Timing Marks

       Courtesy of FORD MOTOR CO.
56. Remove the crankshaft pulley bolt and washer.
    Fig 49: Locating Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" only (orange in color).
Fig 50: Locating Ignition Pulse Wheel
Courtesy of FORD MOTOR CO.
57. Install the ignition pulse wheel.
NOTE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
58. Install the LH and RH spark plugs.
    • Tighten to 15 Nm (133 lb-in).
      Fig 51: Locating Spark Plugs

      Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
NOTE: Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder block-to-oil pan joint.
59. Use a plastic scraping tool to remove all traces of sealant.
    • Clean all sealing surfaces with metal surface prep and install new gaskets.
NOTE: Clean and degrease the sealing surfaces with metal surface prep before applying gasket and sealant.
NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
Fig 52: Locating Silicone Gasket Applying Area Of Cylinder Block
Courtesy of FORD MOTOR CO.
60. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
NOTE: Fasteners 4 and 13 are stud bolts.
61. Position the front cover and install the bolts and stud bolts.
    • Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).
      Fig 53: Identifying Engine Front Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Note the position of the alignment dowel on the engine front cover.
62. Install the 2 bolts and the LH Variable Camshaft Timing (VCT) solenoid.
    • Tighten to 10 Nm (89 lb-in).
      Fig 54: Locating LH VCT With Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Note the position of the alignment dowel on the engine front cover.
63. Install the 2 bolts and the RH VCT  solenoid.
    • Tighten to 10 Nm (89 lb-in).
      Fig 55: Locating RH VCT With Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Clean all sealing surfaces with metal surface prep.
64. Apply clean engine oil to the seal lip and seal bore before installing the seal.
65. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
    Fig 56: Installing Crankshaft Front Seal Using Special Tools

    Courtesy of FORD MOTOR CO.
NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant.
NOTE: Sealing surfaces must be free of dirt and oil.
NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of sealant application.
Fig 57: Locating Silicone Gasket And Sealant Applying Area Of Keyway Slot
Courtesy of FORD MOTOR CO.
66. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
Fig 58: Installing Crankshaft Pulley Using The Crankshaft Vibration Damper Installer
Courtesy of FORD MOTOR CO.
67. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
68. Install the bolt and washer. Tighten the bolt in 4 stages:
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
      Fig 59: Locating Crankshaft Pulley Bolt

      Courtesy of FORD MOTOR CO.
69. Install the belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 60: Locating Accessory Drive Belt Tensioner And Bolts

      Courtesy of FORD MOTOR CO.
70. Install the 8 nuts and the oil pan baffle in the following sequence.
    1. Tighten the 4 M6 oil pan baffle nuts in 2 stages.
       • Stage 1: Tighten to 5 Nm (44 lb-in).
       • Stage 2: Tighten an additional 45 degrees.
    2. Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages.
       • Stage 1: Tighten to 15 Nm (133 lb-in).
       • Stage 2: Tighten an additional 45 degrees.
         Fig 61: Identifying Oil Pan Baffle Nuts Removing Sequence

         Courtesy of FORD MOTOR CO.
71. Install a new O-ring seal on the oil pump screen and pickup tube.
    • Lubricate the O-ring seal with clean engine oil.
      Fig 62: Locating O-Ring Seal

      Courtesy of FORD MOTOR CO.
72. Install the oil pump screen and pickup tube.
    1. Position the oil pump screen and pickup tube.
    2. Install the 2 bolts and tighten to 10 Nm (89 lb-in).
       Fig 63: Identifying Oil Pump Screen And Pickup Tube And Bolts

       Courtesy of FORD MOTOR CO.
73. Install the new gasket in the LH valve cover in the following sequence.
    1. Install the gasket at waffle pads and then the corners.
    2. Install the gasket around bolt holes.
    3. Install the remaining part of the gasket.
       Fig 64: Valve Cover Gasket Installing Sequence

       Courtesy of FORD MOTOR CO.
NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.
NOTE: Clean cylinder head and front cover surface and the cam seal retainer-to-cylinder head surface using metal surface prep before applying silicone gasket and sealant.
Fig 65: Locating Silicone Gasket And Sealant Applying Area Of Cylinder Block
Courtesy of FORD MOTOR CO.
74. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints.
75. Position the LH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 66: Identifying Valve Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
76. Install the new gasket in the RH valve cover in the following sequence.
    1. Install the gasket at waffle pads and then the corners.
    2. Install the gasket around bolt holes.
    3. Install the remaining part of the gasket.
       Fig 67: Identifying Valve Cover Gasket Installing Sequence

       Courtesy of FORD MOTOR CO.
NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.
NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.
Fig 68: Locating Sealant Applying Area Of Front Cover-To-Cylinder Head Joints
Courtesy of FORD MOTOR CO.
77. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
78. Position the RH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 69: Identifying RH Valve Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
79. Install the radio interference capacitor and the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 70: Locating Radio Interference Capacitor With Nut

      Courtesy of FORD MOTOR CO.
80. Position the coolant pump housing and attach the coolant hose.
    • Tighten the clamp to 7 Nm (62 lb-in).
      Fig 71: Locating Coolant Pump Housing And Cooling Hose

      Courtesy of FORD MOTOR CO.
81. Install the 5 coolant pump housing bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 72: Locating Coolant Pump Housing Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
82. Install the Camshaft Pulley Installer in the camshaft as shown in the illustration.
    • Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
      Fig 73: Installing Camshaft Pulley Installer On Camshaft

      Courtesy of FORD MOTOR CO.
NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-458).
83. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration.
    • Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
      Fig 74: Installing Service Coolant Pump Pulley Using Special Tools

      Courtesy of FORD MOTOR CO.
84. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
    Fig 75: Installing Coolant Pump Belt

    Courtesy of FORD MOTOR CO.
NOTE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.
85. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
86. Lubricate the O-ring seal with clean engine oil and install the oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      Fig 76: Locating Oil Filter

      Courtesy of FORD MOTOR CO.
87. Install the Engine Oil Pressure (EOP) switch and, if equipped, the block heater.
    • Tighten the EOP  switch to 14 Nm (124 lb-in).
    • Tighten the block heater to 21 Nm (15 lb-ft).
      Fig 77: Locating EOP Switch And Block Heater

      Courtesy of FORD MOTOR CO.
88. Install 6 new LH catalytic converter studs.
    • Tighten to 12 Nm (106 lb-in).
      Fig 78: Locating RH Exhaust Manifold Studs

      Courtesy of FORD MOTOR CO.
89. Install a new gasket and the LH catalytic converter and 6 new nuts.
    • Tighten in the sequence shown in illustration to 20 Nm (177 lb-in).
      Fig 79: Identifying LH Catalytic Converter Nut Tightening Sequence

      Courtesy of FORD MOTOR CO.
90. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
    Fig 80: Locating O-Ring On Oil Level Indicator Tube

    Courtesy of FORD MOTOR CO.
91. Position the oil level indicator and tube and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 81: Locating Stud Bolt

      Courtesy of FORD MOTOR CO.
92. Install the 3 bolts and the LH heat shield.
    • Tighten to 10 Nm (89 lb-in).
      Fig 82: Locating LH Heat Shield Bolts

      Courtesy of FORD MOTOR CO.
93. Install the 3 bolts and the A/C compressor bracket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 83: Locating A/C Compressor Bracket Bolts

      Courtesy of FORD MOTOR CO.
94. Position the generator and install the bolt and 2 nuts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 84: Locating Generator Nuts And Bolts

      Courtesy of FORD MOTOR CO.
95. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
      Fig 85: Locating RH Exhaust Manifold Studs

      Courtesy of FORD MOTOR CO.
96. Install a new gasket and the RH exhaust manifold and new nuts.
    • Tighten the nuts in 2 stages in the sequence shown in illustration.
      • Stage 1: Tighten to 20 Nm (177 lb-in).
      • Stage 2: Tighten to 20 Nm (177 lb-in).
        Fig 86: Identifying Exhaust Manifold Nuts Tightening Sequence

        Courtesy of FORD MOTOR CO.

    FWD  vehicles

97. Install a new gasket and the RH catalytic converter and the 3 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 87: Locating RH Catalytic Converter Nuts

      Courtesy of FORD MOTOR CO.
98. Install the 3 bolts and the RH heat shield.
    • Tighten to 10 Nm (89 lb-in).
      Fig 88: Locating RH Heat Shield Bolts

      Courtesy of FORD MOTOR CO.
99. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 89: Locating RH Heated Oxygen Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: LH shown in illustration, RH similar.
100. Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

     Install the 6 coil-on-plugs and the bolts.

     • Tighten to 6 Nm (53 lb-in).
       Fig 90: Locating Coil-On-Plugs Bolts

       Courtesy of FORD MOTOR CO.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
101. Position the lower intake manifold and install the 8 bolts.
     • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
       Fig 91: Identifying Lower Intake Manifold Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
102. Install new fuel injector O-rings.
     • Separate the fuel injectors from the fuel rail.
     • Remove and discard the fuel injector O-rings.
     • Install new O-rings and lubricate with clean engine oil.
     • Install the fuel injectors onto the fuel rail.
       Fig 92: Locating Fuel Injector O-Rings

       Courtesy of FORD MOTOR CO.
103. Install the 4 bolts and the fuel rail and injectors assembly.
     • Tighten to 10 Nm (89 lb-in).
       Fig 93: Locating Fuel Rail And Injectors Assembly Bolts

       Courtesy of FORD MOTOR CO.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
104. Position the upper intake manifold and install the 7 bolts.
     • Tighten the bolts in 2 stages in the sequence shown in illustration.
       • Stage 1: Tighten to 10 Nm (89 lb-in).
       • Stage 2: Tighten an additional 45 degrees.
         Fig 94: Upper Intake Manifold Bolts Tightening Sequence

         Courtesy of FORD MOTOR CO.
105. Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown in illustration), then tighten all the bolts.
     • Tighten to 10 Nm (89 lb-in).
       Fig 95: Locating Upper Intake Manifold Bracket Bolts

       Courtesy of FORD MOTOR CO.
106. Install the EGR tube fitting in the EGR valve.
     • Tighten to 40 Nm (30 lb-ft).
       Fig 96: Locating EGR Tube Fitting

       Courtesy of FORD MOTOR CO.
107. Position and attach the 3 B+ wiring harness retainers.
     Fig 97: Locating B+ Wiring Harness Retainers

     Courtesy of FORD MOTOR CO.
108. Install the B+ wire and nut on the generator.
     • Tighten to 8 Nm (71 lb-in).
       Fig 98: Locating Generator B+ Wire And Nut

       Courtesy of FORD MOTOR CO.
109. Connect the 3 LH coil-on-plug electrical connectors.
     • Attach the 2 wiring harness retainers.
       Fig 99: Locating LH Coil-On-Plug Electrical Connectors

       Courtesy of FORD MOTOR CO.
110. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
     Fig 100: Locating LH HO2S Electrical Connector

     Courtesy of FORD MOTOR CO.
111. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.
     Fig 101: Locating Engine Oil Pressure Switch Electrical Connector

     Courtesy of FORD MOTOR CO.
112. Connect the LH VCT  electrical connector.
     Fig 102: Locating LH VCT Electrical Connector

     Courtesy of FORD MOTOR CO.
113. Connect the fuel injector wiring harness electrical connector.
     Fig 103: Locating Fuel Injector Wiring Harness Electrical Connector

     Courtesy of FORD MOTOR CO.
114. Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness retainer from the engine front cover stud bolt.
     Fig 104: Locating Camshaft Position Sensor Electrical Connectors

     Courtesy of FORD MOTOR CO.
115. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring harness retainers.
     Fig 105: Locating Crankshaft Position Sensor Electrical Connector And Wiring Harness Retainers

     Courtesy of FORD MOTOR CO.
116. Connect the RH VCT  electrical connector.
     Fig 106: Locating RH Variable Camshaft Timing Electrical Connector

     Courtesy of FORD MOTOR CO.
117. Connect the RH coil-on-plug electrical connectors.
     • Attach the 2 wiring harness retainers.
       Fig 107: Locating RH Coil-On-Plug Electrical Connectors And Wiring Harness Retainer

       Courtesy of FORD MOTOR CO.

     FWD  vehicles

118. Connect the RH HO2S  electrical connector.
     Fig 108: Locating RH HO2S Electrical Connector

     Courtesy of FORD MOTOR CO.

     All vehicles 

119. Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer.
     Fig 109: Locating Manifold Absolute Pressure Electrical Connector And Wiring Retainer

     Courtesy of FORD MOTOR CO.
120. Attach the wiring harness retainer to the upper intake manifold.
     Fig 110: Locating Wiring Harness Retainer Of Upper Intake Manifold

     Courtesy of FORD MOTOR CO.
121. Connect the EGR regulator electrical connector and attach the wiring retainer.
     Fig 111: Locating EGR Regulator Electrical Connector And Wiring Retainer

     Courtesy of FORD MOTOR CO.
122. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
     Fig 112: Locating Evaporative Emission Canister Purge Valve Electrical Connector

     Courtesy of FORD MOTOR CO.
123. Connect the electronic throttle control electrical connector.
     Fig 113: Locating Electronic Throttle Control Electrical Connector

     Courtesy of FORD MOTOR CO.
124. Connect the engine block Knock Sensor (KS) electrical connector and attach the wire harness retainer, connect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
     Fig 114: Locating Engine Block Knock Sensor And Cylinder Head Temperature (CHT) Electrical Connectors

     Courtesy of FORD MOTOR CO.
125. Using the Spreader Bar and the Engine Lifting Brackets, remove the engine from the engine stand.
     Fig 115: Removing Engine From The Engine Stand Using The Spreader Bar And The Engine Lifting Brackets

     Courtesy of FORD MOTOR CO.