Engine Upper - RH Cylinder Head

Fig 1: Exploded View Of Engine Upper Components (RH Cylinder Head)

Courtesy of FORD MOTOR CO.

Item	Service Part Number	Description
1	12029	Ignition coil-on-plug (3 required)
2	6582	RH valve cover
3	6A258	RH camshaft cap (6 required)
4	6K602	Valve train oil feed tube
5	6K254	RH secondary timing chain tensioner
6	6B280	Camshaft mega cap
7	6M280	Exhaust camshaft VCT oil control solenoid
8	6M280	Intake camshaft VCT oil control solenoid
9	6K297	RH secondary tensioner shoe
10	6C524	Intake camshaft VCT assembly
11	6C525	Exhaust camshaft VCT assembly
12	6268	RH secondary timing chain
13	6250	RH intake camshaft
14	6250	RH exhaust camshaft
15	12405	Spark plug (3 required)
16	6500	Valve tappet (24 required)
17	6B288	RH cylinder head CMP sensor (2 required)
18	6G004	CHT sensor
19	6049	RH cylinder head
20	6051	RH cylinder head gasket

NOTE: This procedure is for selecting bearings using a new crankshaft.

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 face.
3. The first letter after the first asterisk makes up the code for main No. 1 and the next letter for main No. 2. The first letter after the second asterisk makes up the code for main No. 3 and the last letter for main No. 4.
Fig 2: Locating Crankshaft Main Bearings Code Information
Courtesy of FORD MOTOR CO.
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.
1. If the block code is BMQS and the crankshaft code is OLPO, Main No. 1 should be built with grade 1 bearings, as determined by the intersection of the B block column and the O crankshaft row on the chart. Mains No. 2, No. 3 and No. 4 should all be grade 2.
Fig 3: Block And Crankshaft Code Reference Chart
Courtesy of FORD MOTOR CO.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

Using the original connecting rod cap bolts, install the connecting rod caps and bolts. Tighten the bolts in 3 stages.
- Stage 1: Tighten to 23 Nm (17 lb-ft).
- Stage 2: Tighten to 43 Nm (32 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
Measure the connecting rod large end bore in 2 directions.
1. Remove the bolts and the rod cap.
2. Discard the connecting rod cap bolts.
Fig 4: Identifying Connecting Rod Large End Bore Measuring Directions
Courtesy of FORD MOTOR CO.
Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.

Fig 5: Identifying Crankshaft Connecting Rod Bearing Journal Diameters
Courtesy of FORD MOTOR CO.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

Fig 6: Connecting Rod Bearing Selecting 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.

Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.

Fig 7: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
NOTE: Do not install the upper thrust bearings until the crankshaft is installed.

NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.

Install the crankshaft onto the upper main bearings.

Fig 8: Locating Crankshaft Upper Main Bearings
Courtesy of FORD MOTOR CO.
NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.

Fig 9: Installing Rear Crankshaft Upper Thrust Washer
Courtesy of FORD MOTOR CO.
NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.

Fig 10: Installing Front Upper Crankshaft Thrust Washer
Courtesy of FORD MOTOR CO.
Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.

Fig 11: Locating Crankshaft Bearing
Courtesy of FORD MOTOR CO.
Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.

Fig 12: Locating Main Bearing Crankshaft Caps
Courtesy of FORD MOTOR CO.
NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.

Fig 13: Locating Aligned Tab Of Main Bearing
Courtesy of FORD MOTOR CO.
Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.

Fig 14: Locating Main Bearing Cap On Cylinder Block
Courtesy of FORD MOTOR CO.
Loosen the No. 4 main bearing cap bolts.
NOTE: The following steps are for early built engines .

NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1S 342 AA or 1S 344 AA) and late build engines are built with engine code (1S 342 BA or 1S 344 BA).

NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.

Early built engines, tighten the main bearing bolts in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten fasteners 1 through 8 to 60 Nm (44 lb-ft).
- Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
Fig 15: Identifying Tightening Sequence Of Main Bearing Bolts
Courtesy of FORD MOTOR CO.
Early built engines, install the new 8 main bearing cap side bolts. Tighten in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten fasteners 1 through 8 to 45 Nm (33 lb-ft).
- Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
Fig 16: Identifying Tightening Sequence Main Bearing Cap Side Bolts
Courtesy of FORD MOTOR CO.
NOTE: The following steps are for late built engines .

NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of ((1S 342 AA or 1S 244 AA) and late build engines are built with engine code (1S 342 BA or 1S 344 BA) .

NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.

Late built engines, tighten the main bearing bolts in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten fasteners 1 through 8 to 33 Nm (24 lb-ft).
- Stage 2: Tighten fasteners 1 through 8 an additional 135 degrees.
Fig 17: Identifying Tightening Sequence Of Main Bearing Bolts
Courtesy of FORD MOTOR CO.
Late built engines, install the new 8 main bearing cap side bolts. Tighten in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten fasteners 1 through 8 to 24 Nm (18 lb-ft).
- Stage 2: Tighten fasteners 1 through 8 an additional180 degrees.
Fig 18: Identifying Tightening Sequence Of Bearing Cap Side Bolts
Courtesy of FORD MOTOR CO.
Using 100-002 (TOOL-4201-C), measure crankshaft end play.
1. Position the crankshaft to the rear of the cylinder block.
2. Zero 100-002 (TOOL-4201-C).
3. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Fig 19: Measuring Crankshaft End Play
Courtesy of FORD MOTOR CO.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

Prepare the connecting rod and cap.
1. Insert the new bolts in the rod cap.
2. Insert the upper and lower rod bearings into the rod and cap.
Fig 20: Locating Connecting Rod And Cap
Courtesy of FORD MOTOR CO.
Before installing the pistons into the cylinder block, verify proper ring gap location.
1. Center line of the piston parallel to the wrist pin bore.
2. Upper compression ring gap location.
3. Upper oil control segment ring gap location.
4. Lower oil control segment ring gap location.
5. Expander ring and lower compression ring gap location.
Fig 21: Identifying Piston Rings Installation Position Onto Piston
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: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown in illustration.

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 Piston .

NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.

NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.

Using the Piston Ring Compressor, install the piston and connecting rod assemblies.

Fig 22: Installing Piston And Connecting Rod Assemblies Using Piston Ring Compressor
Courtesy of FORD MOTOR CO.
Seat the connecting rod on the crankshaft journal.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

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

Install the connecting rod cap and bolts. Tighten the bolts in 3 stages.
- Stage 1: Tighten to 23 Nm (17 lb-ft).
- Stage 2: Tighten to 43 Nm (32 lb-ft).
- Stage 3: Tighten an additional degrees (90).
Fig 23: Locating Connecting Rod Cap And Bolts
Courtesy of FORD MOTOR CO.
Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in illustration in 2 steps.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 180 degrees.
Fig 24: Identifying Main Bearing Cap Support Brace Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.

Apply a 3 mm (0.12 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.

Fig 25: Applying Bead Of Silicone On Crankshaft Rear Seal Retainer
Courtesy of FORD MOTOR CO.
Install the crankshaft rear seal retainer and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).
Fig 26: Identifying Crankshaft Rear Seal Retainer And Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the oil pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
Fig 27: Locating Oil Pump With Bolts
Courtesy of FORD MOTOR CO.
Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
Fig 28: Locating Oil Pump Screen And Pickup Tube With Bolts
Courtesy of FORD MOTOR CO.
NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.

Install the A/C compressor and the 2 bolts.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
Fig 29: Locating A/C Compressor Mounting Bolts
Courtesy of FORD MOTOR CO.
NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

Apply a 3 mm (0.12 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan.
1. Apply a 5.5 mm (0.22 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
Fig 30: Location of Bead Of Motorcraft High Performance Engine RTV Silicone
Courtesy of FORD MOTOR CO.
NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

Install the oil pan and bolts 10, 11, 13 and 14.
- Stage 1: Tighten to 3 Nm (27 lb-in).
- Stage 2: Loosen the bolts 180 degrees.
Fig 31: Identifying Oil Pan And Bolts 10, 11, 13 And 14 Tightening Sequence
Courtesy of FORD MOTOR CO.
Align the oil pan to the cylinder block and the A/C compressor.
1. Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown in illustration.
Fig 32: Aligning Oil Pan To Cylinder Block And A/C Compressor
Courtesy of FORD MOTOR CO.
Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration, to 3 Nm (27 lb-in).

Fig 33: Identifying Oil Pan And Bolts 10, 11, 13 And 14 Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown in illustration.
- Stage 1: Tighten the large bolts (1-14) to 24 Nm (18 lb-ft).
- Stage 2: Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
Fig 34: Identifying Oil Pan Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the A/C compressor mounting stud and nut.
- Tighten the stud to 9 Nm (80 lb-in) and the nut to25 Nm (18 lb-ft).
Fig 35: Locating A/C Compressor Nut And Stud
Courtesy of FORD MOTOR CO.
Install the coolant pump and the 8 bolts. Tighten in the sequence shown in illustration in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 36: Identifying Coolant Pump Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the KS and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Fig 37: Locating Knock Sensor And Bolts
Courtesy of FORD MOTOR CO.
NOTE: Early built coolant tube shown in illustration, late build coolant tube similar.

NOTE: Apply clean engine coolant to the O-ring seal prior to installation.

Using a new O-ring seal, install the coolant inlet tube and thermostat assembly.

Fig 38: Locating Coolant Inlet Tube And Thermostat Assembly
Courtesy of FORD MOTOR CO.
Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 35 Nm (26 lb-ft).
- Stage 3: Tighten 90 degrees.
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten 45 degrees.
Fig 39: Identifying RH Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 40: Locating RH Cylinder Head M6 Bolt
Courtesy of FORD MOTOR CO.
Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 35 Nm (26 lb-ft).
- Stage 3: Tighten 90 degrees.
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten 45 degrees.
Fig 41: Identifying LH Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 42: Locating LH Cylinder Head M6 Bolt
Courtesy of FORD MOTOR CO.
NOTE: The valve tappets must be installed in their original positions.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

NOTE: LH shown in illustration, RH similar.

Install the valve tappets.

Fig 43: Locating Valve Tappets
Courtesy of FORD MOTOR CO.
NOTE: Align the bracket with the index mark made during removal.

Install the upper intake manifold bracket and the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 44: Locating Upper Intake Manifold Bracket And Bolt
Courtesy of FORD MOTOR CO.
Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
Fig 45: Locating Engine Lifting Eye And Mounting Bolts
Courtesy of FORD MOTOR CO.
Install the RH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 46: Locating RH Primary Timing Chain Guide And Bolt
Courtesy of FORD MOTOR CO.
NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

Position the crankshaft dowel pin in the 9 o'clock position.

Fig 47: Locating Crankshaft Dowel Pin
Courtesy of FORD MOTOR CO.
NOTE: Coat the camshafts with clean engine oil prior to installation.

Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.

Fig 48: Locating Crankshaft Dowel Pin In 9 O'Clock Position
Courtesy of FORD MOTOR CO.
NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

Position the 4 camshaft seals gaps as shown in illustration.

Fig 49: Locating Camshaft Seals Gaps
Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration.
- Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 50: Identifying Camshaft Caps, Mega Cap, Valve Train Oil Tube Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Loosen the 4 camshaft caps bolts.

Fig 51: Locating Camshaft Caps Bolts
Courtesy of FORD MOTOR CO.
Tighten the 4 camshaft caps bolts in the sequence shown in illustration.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 52: Identifying Camshaft Caps Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size.

Fig 53: Measuring Valve Tappet Clearance
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the RH valve train oil tube.

Fig 54: Locating RH Valve Train Oil Tube Bolts
Courtesy of FORD MOTOR CO.
Rotate the RH camshafts to the TDC position as shown in illustration.

Fig 55: Locating TDC Position Of RH Camshafts
Courtesy of FORD MOTOR CO.
NOTE: The 303-1248 will hold the camshafts in the TDC position.

Install 303-1248 onto the flats of the RH camshafts.

Fig 56: Identifying Camshaft Holding Tool On RH Camshafts
Courtesy of FORD MOTOR CO.
Compress the RH secondary timing chain tensioner and Install 303-1530 to retain the tensioner in the collapsed position.

Fig 57: Compressing RH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
1. Align the colored links with the timing marks.
Fig 58: Aligning Colored Links With Timing Marks
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.

Fig 59: Locating RH VCT Assemblies And Secondary Timing Chain
Courtesy of FORD MOTOR CO.
Install the 2 new RH VCT bolts and tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
Fig 60: Locating RH VCT Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: The 2 VCT oil control solenoids are removed for clarity.

Compress the RH secondary timing chain tensioner and remove The 303-1530 .
1. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
Fig 61: Compressing RH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
NOTE: Coat the camshafts with clean engine oil prior to installation.

Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.

Fig 62: Locating Neutral Position LH Cylinder Head Camshafts
Courtesy of FORD MOTOR CO.
NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

Position the 4 camshaft seals gaps as shown in illustration.

Fig 63: Locating Camshaft Seals Gaps
Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration.
- Tighten to 8 Nm (71 lb-in).
Fig 64: Identifying Camshaft Caps, Mega Cap And Valve Train Oil Tube Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Loosen the 4 camshaft caps bolts.

Fig 65: Locating Camshaft Caps Bolts
Courtesy of FORD MOTOR CO.
Tighten the 4 camshaft caps bolts in the sequence shown in illustration.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 66: Identifying Camshaft Caps Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size.

Fig 67: Measuring Valve Tappet Clearance
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the LH valve train oil tube.

Fig 68: Locating LH Valve Train Oil Tube And Mounting Bolts
Courtesy of FORD MOTOR CO.
Rotate the LH camshafts to the TDC position as shown in illustration.

Fig 69: Locating LH Camshafts To TDC Position
Courtesy of FORD MOTOR CO.
NOTE: The 303-1248 will hold the camshafts in the TDC position.

Install 303-1248 onto the flats of the LH camshafts.

Fig 70: Identifying Camshaft Holding Tool On LH Camshafts
Courtesy of FORD MOTOR CO.
Compress the LH secondary timing chain tensioner and install The 303-1530 to retain the tensioner in the collapsed position.

Fig 71: Compressing LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
1. Align the colored links with the timing marks.
Fig 72: Aligning Colored Links With Timing Marks
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.

Fig 73: Locating LH VCT Assemblies And Secondary Timing Chain
Courtesy of FORD MOTOR CO.
Install the 2 new LH VCT bolts and tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 25 Nm (18 lb-ft).
- Stage 4: Tighten an additional 180 degrees.
Fig 74: Locating LH VCT Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: The 2 VCT oil control solenoids are removed for clarity.

Compress the LH secondary timing chain tensioner and remove The 303-1530 .
1. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
Fig 75: Compressing LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Install the LH upper primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 76: Locating Upper LH Primary Timing Chain Guide And Mounting Bolts
Courtesy of FORD MOTOR CO.
Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).

Fig 77: Locating Crankshaft Dowel Pin At 11 O'Clock
Courtesy of FORD MOTOR CO.
Install the crankshaft timing chain sprocket.

Fig 78: Locating Crankshaft Timing Chain Sprocket
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.

Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.

Fig 79: Aligning Primary Timing Chain Colored Links With Timing Marks On VCT Assemblies And Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the lower LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
Fig 80: Locating Lower LH Primary Timing Chain Guide And Mounting Bolts
Courtesy of FORD MOTOR CO.
Install the primary timing chain tensioner arm.

Fig 81: Locating Primary Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
Reset the primary timing chain tensioner.
1. Release the ratchet detent.
2. Using a soft-jawed vise, compress the ratchet plunger.
3. Align the hole in the ratchet plunger with the hole in the tensioner housing.
4. Install a suitable lockpin.
Fig 82: Resetting Primary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

Install the primary tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the lockpin.
Fig 83: Locating Primary Tensioner, Bolts And Lockpin
Courtesy of FORD MOTOR CO.
As a post-check, verify correct alignment of all timing marks.
1. There are 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
2. There are 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
Fig 84: Verifying Correct Alignment Of All Timing Chains Colored Links And Timing Marks
Courtesy of FORD MOTOR CO.
NOTE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.

NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

Install the LH intake VCT oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
Fig 85: Locating LH Intake VCT Oil Control Solenoid And Mounting Bolt
Courtesy of FORD MOTOR CO.
NOTE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.

NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

Install the RH intake VCT oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
Fig 86: Locating RH Intake VCT Oil Control Solenoid And Mounting Bolt
Courtesy of FORD MOTOR CO.
Remove the RH 303-1248 .

Fig 87: Installing Camshaft Holding Tool Onto Flats Of RH Camshafts
Courtesy of FORD MOTOR CO.
Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 88: Locating RH Valve Train Oil Tube Bolts
Courtesy of FORD MOTOR CO.
Remove the LH 303-1248 .

Fig 89: Installing Camshaft Holding Tool Onto Flats Of LH Camshafts
Courtesy of FORD MOTOR CO.
Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 90: Locating LH Valve Train Oil Tube And Mounting Bolts
Courtesy of FORD MOTOR CO.
NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTE: Do not use wire brushes, power abrasive discs or 3M Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces of engine block, cylinder heads, and oil pan. These tools can cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
1. Remove any large deposits of silicone or gasket material.
2. Apply Motorcraft® Silicone Gasket Remover and allow to set for several minutes.
3. Remove the Motorcraft® Silicone Gasket Remover. A second application of Motorcraft® Silicone Gasket Remover may be required if residual traces of silicone or gasket material remain.
4. Apply Motorcraft® Metal Surface Prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install 307-399 .

Fig 91: Identifying Cylinder Block Dowel Pins
Courtesy of FORD MOTOR CO.
NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use Motorcraft® Silicone Gasket Remover and Motorcraft® Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

Apply a 3 mm (0.1181 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the front cover.
- Apply a 5.5 mm (0.22 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
Fig 92: Locating RTV Silicone Applying Area On Engine Front Cover Sealing Surfaces
Courtesy of FORD MOTOR CO.
NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22.
- Tighten in sequence shown in illustration to 3 Nm (27 lb-in).
Fig 93: Identifying Tightening Sequence Of Engine Front Cover Mounting Bolts
Courtesy of FORD MOTOR CO.
Remove 307-399 .

Fig 94: Identifying Cylinder Block Dowel Pins
Courtesy of FORD MOTOR CO.
Install the M6 engine front cover bolt. Do not tighten at this time.

Fig 95: Locating M6 Engine Front Cover Bolt
Courtesy of FORD MOTOR CO.
Install the 2 upper M10 engine front cover bolts. Do not tighten the bolts at this time.

Fig 96: Locating Engine Front Cover (M6) Bolt
Courtesy of FORD MOTOR CO.
Install the lower M10 bolt. Do not tighten at this time.

Fig 97: Locating Lower M10 Engine Front Cover Bolt
Courtesy of FORD MOTOR CO.
Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in illustration in 7 stages.
- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 23 thru 25 to 15 Nm (133 lb-in).
- Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in).
- Stage 4: Loosen bolt 26 one full turn.
- Stage 5: Tighten bolts 23 thru 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees.
- Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees.
- Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.
Fig 98: Identifying Tightening Sequence Of Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using 303-1247/2 and 205-153 (T80T-4000-W) install the new spark plug tube seal(s).

Fig 99: Installing Spark Plug Tube Seals
Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using 205-142 (T80T-4000-J) and 205-153 (T80T-4000-W) install the new VCT seal(s).

Fig 100: Installing VCT Solenoid Seals
Courtesy of FORD MOTOR CO.
NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Motorcraft® Silicone Gasket Remover and Motorcraft® Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.315 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

Fig 101: Installing VCT Seal Using Tool
Courtesy of FORD MOTOR CO.
Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
Fig 102: Identifying RH Valve Cover Bolts And Stud Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.

Fig 103: Identifying VCT Seal Position
Courtesy of FORD MOTOR CO.
Install the 3 RH coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).
Fig 104: Locating RH Ignition Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using 303-1247/2 and 205-153 (T80T-4000-W) install the new spark plug tube seal(s).

Fig 105: Installing Spark Plug Tube Seals
Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using 205-142 (T80T-4000-J) and 205-153 (T80T-4000-W) install the new VCT seal(s).

Fig 106: Installing VCT Seals
Courtesy of FORD MOTOR CO.
NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Motorcraft® Silicone Gasket Remover and Motorcraft® Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.315 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

Fig 107: Locating Bead Of Motorcraft High Performance Engine RTV Silicone Applying Areas
Courtesy of FORD MOTOR CO.
Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
Fig 108: Identifying LH Valve Cover Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.

Fig 109: Identifying VCT Seal Position
Courtesy of FORD MOTOR CO.
Install the 3 LH coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).
Fig 110: Locating LH Ignition Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
NOTE: Engine without oil cooler shown in illustration, engine with oil cooler similar.

Using a new gasket, install the oil filter adapter and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
Fig 111: Locating Oil Filter Adapter And Bolts
Courtesy of FORD MOTOR CO.
NOTE: A new oil cooler must be installed or severe damage to the engine may occur.

If equipped, install a new oil cooler, new gaskets and the 6 bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
Fig 112: Identifying Oil Cooler Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Apply Thread Sealant with PTFE to the EOP switch threads.

Install the EOP switch.
- Tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.
Fig 113: Locating EOP Switch
Courtesy of FORD MOTOR CO.
Install the CKP sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 114: Locating EOP Switch
Courtesy of FORD MOTOR CO.
Install and connect the CHT sensor jumper harness.

Fig 115: Locating CHT Sensor Jumper Harness Connector
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.

Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
Fig 116: Installing Lower Intake Manifold With Tightening Squence
Courtesy of FORD MOTOR CO.
Install the 2 thermostat housing-to-lower intake manifold bolts.
- Tighten to 10 Nm (89 lb-in).
Fig 117: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
Install the 2 bolts and the 2 LH CMP sensors.
- Tighten to 10 Nm (89 lb-in).
Fig 118: Locating LH CMP Sensors And Bolts
Courtesy of FORD MOTOR CO.
Install the 2 bolts and the 2 RH CMP sensors.
- Tighten to 10 Nm (89 lb-in).
Fig 119: Locating CMP Sensors And Bolts
Courtesy of FORD MOTOR CO.
Install the cover and the pin-type retainer.

Fig 120: View Of Cover And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
If equipped, install the block heater wiring harness onto the engine.
- Stage 1: Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 180 degrees.
- Stage 2: Tighten the block heater to 40 Nm (30 lb-ft).
Fig 121: Locating RH Cylinder Block Drain Plug Or Block Heater
Courtesy of FORD MOTOR CO.
Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
Fig 122: Locating LH Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
Fig 123: Locating RH Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
Fig 124: Locating RH Exhaust Manifold Studs With Tightening Sequence
Courtesy of FORD MOTOR CO.
If equipped with FWD, using a new gasket, install the RH catalytic converter and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).
Fig 125: Locating RH Catalytic Converter And Fasteners
Courtesy of FORD MOTOR CO.
Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
Fig 126: Locating LH Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
Using a new gasket, install the LH catalytic converter and 3 new lower LH catalytic converter manifold-to-cylinder head nuts. Tighten in 2 stages in the sequence shown in illustration:
- Stage 1: Tighten the 3 lower LH catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).
- Stage 2: Install the 3 new upper nuts and tighten the upper LH catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).
Fig 127: Locating LH Catalytic Converter And Nuts
Courtesy of FORD MOTOR CO.
Install the LH exhaust heat shield and the 3 bolts.
- Tighten to 12 Nm (106 lb-in).
Fig 128: Locating LH Exhaust Heat Shield Bolts
Courtesy of FORD MOTOR CO.
NOTE: Apply High Temperature Nickel Anti-Seize Lubricant to the threads of the HO2S prior to installing.

Install the LH HO2S .
- Tighten to 48 Nm (35 lb-ft).
Fig 129: Locating LH HO2S
Courtesy of FORD MOTOR CO.
Install the generator, the bolt and the nut.
- Tighten to 48 Nm (35 lb-ft).
Fig 130: Locating Generator Stud, Nut And Bolt
Courtesy of FORD MOTOR CO.
Connect the EOP switch electrical connector and the wiring harness pin-type retainer.

Fig 131: Locating Engine Oil Pressure (EOP) Switch Electrical Connector And Retainer
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the generator.

Fig 132: Location of Wiring Harness Retainer At Generator
Courtesy of FORD MOTOR CO.
Connect the generator electrical connector.
Connect the generator B+ cable and install the nut.
- Tighten to 7 Nm (62 lb-in).
Fig 133: Locating Generator B+ Cable Nut
Courtesy of FORD MOTOR CO.
Connect the A/C compressor electrical connector.

Fig 134: Locating A/C Compressor Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the CKP sensor electrical connector.

Fig 135: Locating Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the wiring harness grommet.

Fig 136: Location of Wiring Harness Grommet
Courtesy of FORD MOTOR CO.
Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 137: View Of Wiring Harness Retainer Stud Bolt
Courtesy of FORD MOTOR CO.
Install the heat shield, the nut and the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 138: Locating Heat Shield With Bolt And Nut
Courtesy of FORD MOTOR CO.
Install the ground cable and the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 139: Locating RH Cylinder Head Ground Cable And Bolt
Courtesy of FORD MOTOR CO.
Connect the CHT sensor electrical connector.

Fig 140: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the KS electrical connector.

Fig 141: Locating Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 2 RH CMP sensor electrical connectors.

Fig 142: Locating RH CMP Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer.

Fig 143: View Of Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the 3 fuel injector electrical connectors and attach the 2 wiring harness retainers to the RH valve cover stud bolts.

Fig 144: Locating Fuel Injector Electrical Connectors And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the 2 VCT oil control solenoid electrical connectors and attach the 2 oil control solenoid wiring harness retainers.

Fig 145: VCT Oil Control Solenoid Electrical Connectors And Harness Retainers
Courtesy of FORD MOTOR CO.
Attach the 2 wiring harness retainers from the RH valve cover.

Fig 146: Locating HO2S, CMS Electrical Connectors And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the 3 RH coil-on-plug electrical connectors. ignition coils.

Fig 147: Locating RH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Using a new gasket, install the intake manifold and the 7 bolts.
1. Tighten in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 148: Install The Intake Manifold And Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the upper intake manifold support bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 149: Locating Upper Intake Manifold Support Bracket Bolt
Courtesy of FORD MOTOR CO.
Connect the crankcase ventilation hose to the PCV valve. REFER to QUICK CONNECT COUPLING .

Fig 150: Locating Crankcase Ventilation Hose
Courtesy of FORD MOTOR CO.
Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.

Fig 151: Locating Wiring Harness/Coolant Tube Retainers
Courtesy of FORD MOTOR CO.
Connect the EVAP canister vent solenoid and throttle body electrical connectors.
1. Attach the 2 wiring harness pin-type retainers.
Fig 152: Locating EVAP Canister Vent Solenoid And Throttle Body Electrical Connectors
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the intake manifold.

Fig 153: Locating Wiring Harness Retainer Of Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the LH CMS electrical connector.
1. Install the wiring harness retainer to the rear of the LH cylinder head.
Fig 154: Locating LH CMS Electrical Connector And Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Connect the 2 LH CMP sensor electrical connectors.

Fig 155: Identifying LH CMP Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: Coolant hose removed from graphic for clarity.

Attach the wiring harness retainer.

Fig 156: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Connect the 3 fuel injector electrical connectors and attach the 2 wiring harness retainers to the LH valve cover stud bolts.

Fig 157: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the LH HO2S electrical connector and attach the wiring harness connector pin-type retainer to the LH valve cover.

Fig 158: Locating HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Attach the 2 wiring harness pin-type retainers.

Fig 159: Locating Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Connect the 2 VCT oil control solenoid electrical connectors and attach the 2 oil control solenoid wiring harness pin-type retainers (1 shown in illustration).

Fig 160: View Of VCT Oil Control Solenoid Electrical Connectors And Harness Retainer
Courtesy of FORD MOTOR CO.
Attach the 3 wiring harness retainers to the LH valve cover stud bolts.

Fig 161: View Of Wiring Harness Retainers To The LH Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
Install the oil level indicator.

Fig 162: Locating Oil Level Indicator
Courtesy of FORD MOTOR CO.
Connect the 3 LH coil-on-plug electrical connectors.

Fig 163: Locating LH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the crankcase vent tube. REFER to QUICK CONNECT COUPLING .

Fig 164: Locating Crankcase Vent Tube
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Using The 303-102 (T74P-6316-B) and 303-1251 , install a new crankshaft front seal.

Fig 165: Installing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the crankshaft front seal inner lip with clean engine oil.

NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using The 303-102 (T74P-6316-B) and 303-335 (T88T-6701-A), install the crankshaft pulley.

Fig 166: Installing Crankshaft Pulley Using Tools
Courtesy of FORD MOTOR CO.
Using The 303-D055 (D85L-6000-A), install the crankshaft pulley washer and new bolt and tighten 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 167: Installing Crankshaft Pulley Washer And New Bolt
Courtesy of FORD MOTOR CO.
Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
Fig 168: Locating Accessory Drive Belt Tensioner And Bolts
Courtesy of FORD MOTOR CO.
If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.
If equipped, connect the block heater electrical connector and install the heat shield.

Fig 169: Locating Block Heater Electrical Connector And Heat Shield
Courtesy of FORD MOTOR CO.
Install 303-1245 on the LH cylinder head.

Fig 170: Installing LH Cylinder Head Using Engine Lift Eye
Courtesy of FORD MOTOR CO.
Using 300-OTC1819E and 303-D089 (D93P-6001-A3), remove the engine from the stand.

Fig 171: Using Spreader Bar And Floor Crane To Move Engine
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position 303-1250 onto the end of the crankshaft and slide a new crankshaft rear seal onto 303-1250 .

Fig 172: Installing Crankshaft Rear Seal Using Rear Main Seal Installer And Handle
Courtesy of FORD MOTOR CO.
Using The 303-1250 and 205-153 (T80T-4000-W), install the new crankshaft rear seal.

Fig 173: Installing Crankshaft Rear Seal
Courtesy of FORD MOTOR CO.
Install the crankshaft sensor ring.

Fig 174: Locating Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.

Install the flexplate and the 8 bolts.
- Tighten in the sequence shown in illustration to 80 Nm (59 lb-ft).
Fig 175: Identifying Flexplate Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.