Lower Engine Block (View 2)

Fig 1: Exploded View Of Lower Engine Block

Courtesy of FORD MOTOR CO.

All vehicles 

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

   Select the crankshaft main bearings for each crankshaft journal.

   • Read the code on the crankshaft flange.
   • Read the code on the cylinder block face.
     • 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 Code On Crankshaft Flange And Code On Cylinder Block Face

       Courtesy of FORD MOTOR CO.
2. NOTE: This chart is for selecting main bearings 1 and 4 only, the remaining bearings will be selected using a different chart in the next step.

   Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4.

   • 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(s) for the No. 1 crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing.
   • Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
     Fig 3: Main Bearings Selection Chart (Bearings 1 And 4)

     Courtesy of FORD MOTOR CO.
3. NOTE: This chart is for selecting main bearings 2 and 3 only.

   Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3.

   • Read the second letter of the engine block main bearing code and the second 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. 2 crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is "1".
   • Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
     Fig 4: Main Bearings Selection Chart (Bearings 2 And 3)

     Courtesy of FORD MOTOR CO.
4. 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.
5. Measure the connecting rod large end bore in 2 directions.
   • Remove the bolts and the rod cap.
     • Discard the connecting rod cap bolts.
       Fig 5: Identifying Connecting Rod Large End Bore Measuring Directions

       Courtesy of FORD MOTOR CO.
6. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
   Fig 6: Identifying Crankshaft Connecting Rod Bearing Journal Diameters Measuring Directions

   Courtesy of FORD MOTOR CO.
7. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
   Fig 7: Connecting Rod Bearings Selection Chart

   Courtesy of FORD MOTOR CO.
8. 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 8: Locating Crankshaft Main Bearings

   Courtesy of FORD MOTOR CO.
9. 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 9: Locating Thrust Surfaces Of Crankshaft

   Courtesy of FORD MOTOR CO.
10. 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 10: Installing Rear Crankshaft Upper Thrust Washer

    Courtesy of FORD MOTOR CO.
11. 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 11: Installing Front Upper Crankshaft Thrust Washer

    Courtesy of FORD MOTOR CO.
12. 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 12: Locating Crankshaft Lower Main Bearings

    Courtesy of FORD MOTOR CO.
13. 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 13: Locating Main Bearing Caps

    Courtesy of FORD MOTOR CO.
14. 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 14: Locating Lower Crankshaft Thrust Washer And Main Bearing Cap Cutout

    Courtesy of FORD MOTOR CO.
15. 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 15: Locating Main Bearing Cap

    Courtesy of FORD MOTOR CO.
16. Loosen the No. 4 main bearing cap bolts.
17. 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.

    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 16: Identifying Main Bearing Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
18. 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 additional 180 degrees.
      Fig 17: Identifying Main Bearing Cap Side Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
19. 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.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
      Fig 18: Measuring Crankshaft End Play

      Courtesy of FORD MOTOR CO.
20. 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.

    • Insert the new bolts in the rod cap.
    • Insert the upper and lower rod bearings into the rod and cap.
      Fig 19: Locating Upper, Lower Rod Bearings And Rod Cap Bolts

      Courtesy of FORD MOTOR CO.
21. 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 20: Identifying Piston Rings Installation Position Onto Piston

       Courtesy of FORD MOTOR CO.
22. 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 21: Installing Piston And Connecting Rod Assemblies

    Courtesy of FORD MOTOR CO.
23. Seat the connecting rod on the crankshaft journal.
24. 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 90 degrees.
      Fig 22: Locating Connecting Rod Cap And Bolts

      Courtesy of FORD MOTOR CO.
25. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
26. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in illustration in 2 steps.
    • Stage 1: Tighten fasteners to 20 Nm (177 lb-in).
    • Stage 2: Tighten fasteners an additional 180 degrees.
      Fig 23: Identifying Main Bearing Cap Support Brace Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
27. 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.
    NOTE: Cast aluminum (early build) crankshaft rear seal retainer plate shown in illustration, stamped steel (late build) crankshaft rear seal retainer plate is similar.
    NOTE: The stamped steel (late build) crankshaft rear seal retainer plate comes with the crankshaft rear seal.

    Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.

    Fig 24: Locating Bead Of Motorcraft High Performance Engine RTV Silicone Applying Area

    Courtesy of FORD MOTOR CO.
28. Install the crankshaft rear seal retainer and the 8 bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 25: Identifying Crankshaft Rear Seal Retainer Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
29. Install the oil pump and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 26: Locating Bolts And Oil Pump

      Courtesy of FORD MOTOR CO.
30. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
31. 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 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 (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan-to-engine block mating surface.

32. Apply a 5.5 mm (0.21 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.
33. 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 finger tight.

    Fig 27: Identifying Oil Pan Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
34. Laterally align the oil pan to the block. Make sure the oil pan is flush with the block at these 2 points.
    Fig 28: Aligning Oil Pan To Block

    Courtesy of FORD MOTOR CO.
35. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration to 3 Nm (27 lb-in).
    Fig 29: Identifying Oil Pan Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
36. Install the remaining oil pan bolts and tighten in the sequence shown in illustration.
    • Tighten bolts 1-9 and 11-14 to 20 Nm (177 lb-in), then rotate an additional 45 degrees.
    • Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees.
    • Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.
      Fig 30: Identifying Oil Pan Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
37. Install the Knock Sensor (KS) and the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 31: Locating Knock Sensor Bolts

      Courtesy of FORD MOTOR CO.
38. 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 32: Identifying RH Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
39. Install the M6 bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 33: Locating M6 Bolt

      Courtesy of FORD MOTOR CO.
40. 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 34: Identifying LH Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
41. Install the M6 bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 35: Locating M6 Bolt

      Courtesy of FORD MOTOR CO.
42. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
    Fig 36: Locating CHT Sensor Jumper Harness

    Courtesy of FORD MOTOR CO.
43. 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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Using new lower intake manifold gaskets, install the lower intake manifold and the 10 bolts and tighten in the sequence shown in illustration.

    • Tighten to 10 Nm (89 lb-in).
      Fig 37: Identifying Lower Intake Manifold Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
44. 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 38: Locating Valve Tappets

    Courtesy of FORD MOTOR CO.
45. 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 39: Locating LH Camshaft Bearing Caps Bolts

    Courtesy of FORD MOTOR CO.
46. 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.

47. 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 40: Locating Camshaft Seals Gaps

    Courtesy of FORD MOTOR CO.
48. 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 additional 45 degrees.
      Fig 41: Identifying Camshaft Caps, Mega Cap, Valve Train Oil Tube Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
49. Loosen the 4 camshaft caps bolts.
    Fig 42: Locating Camshaft Caps Bolts

    Courtesy of FORD MOTOR CO.
50. 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 additional 45 degrees.
      Fig 43: Identifying Camshaft Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
51. 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. For additional information, refer to VALVE CLEARANCE CHECK .

    Fig 44: Measuring Valve Clearance

    Courtesy of FORD MOTOR CO.
52. Remove the 3 bolts and the RH valve train oil tube.
53. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown in illustration.
54. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install the Camshaft Holding Tool onto the flats of the RH camshafts.

55. 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.

56. 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 45: Locating Camshaft Seals Gaps

    Courtesy of FORD MOTOR CO.
57. 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 additional 45 degrees.
      Fig 46: Identifying Camshaft Caps, Mega Cap, Valve Train Oil Tube And Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
58. Loosen the 4 camshaft caps bolts.
    Fig 47: Locating Camshaft Caps Bolts

    Courtesy of FORD MOTOR CO.
59. 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 additional 45 degrees.
      Fig 48: Identifying Camshaft Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
60. 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. For additional information, refer to VALVE CLEARANCE CHECK .

    Fig 49: Measuring Valve Clearance

    Courtesy of FORD MOTOR CO.
61. Remove the 3 bolts and the LH valve train oil tube.
62. Rotate the LH camshafts to the TDC position as shown in illustration.
63. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install the Camshaft Holding Tool onto the flats of the LH camshafts.

64. Using a new gasket, install the channel cover plate and the 9 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.
65. Install the RH primary timing chain guide and the bolt.
    • Tighten to 10 Nm (89 lb-in).

    Engines with secondary timing chain tensioner removed 

    NOTE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed or damage to the engine may occur.
66. NOTE: Apply clean engine oil to the secondary timing chain tensioner O-ring seals and mega cap bore.
    NOTE: Do not remove the secondary timing chain tensioner shipping clip, until instructed to do so.

    Install the RH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.

67. Install the RH secondary timing chain tensioner shoe.
68. Remove and discard the RH secondary timing chain tensioner shipping clip.
69. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
    • Align the colored links with the timing marks.
70. 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.

71. 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 to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
72. Activate the RH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
73. 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 exhaust VCT oil control solenoid.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
74. NOTE: Apply clean engine oil to the secondary timing chain tensioner O-ring seals and mega cap bore.
    NOTE: Do not remove the secondary timing chain tensioner shipping clip, until instructed to do so.

    Install the LH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.

75. Install the LH secondary timing chain tensioner shoe.
76. Remove and discard the LH secondary timing chain tensioner shipping clip.
77. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
    • Align the colored links with the timing marks.
78. 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.

79. 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.
80. Activate the LH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
81. 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 exhaust VCT oil control solenoid.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.

      Engines with secondary timing chain tensioner not removed 

82. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
83. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
    • Align the colored links with the timing marks.
84. 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.

85. 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 to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
86. NOTE: The 2 VCT oil control solenoids are removed for clarity.

    Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.

    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.
87. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
88. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
    • Align the colored links with the timing marks.
89. 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.

90. 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.
91. NOTE: The 2 VCT oil control solenoids are removed for clarity.

    Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.

    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.

    All engines 

92. Install the upper LH primary timing chain guide and the bolt.
    • Tighten to 10 Nm (89 lb-in).
93. Rotate the crankshaft clockwise to the TDC position (crankshaft dowel pin at 11 o'clock).
    Fig 50: Locating Crankshaft Dowel Pin

    Courtesy of FORD MOTOR CO.
94. Install the crankshaft timing chain sprocket with timing dot mark out.
95. 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 51: Locating Timing Marks On VCT Assemblies And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
96. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
97. Install the primary timing chain tensioner arm.
98. Reset the primary timing chain tensioner.
    • Release the ratchet detent.
    • Using a soft-jawed vise, compress the ratchet plunger.
    • Align the hole in the ratchet plunger with the hole in the tensioner housing.
    • Install a suitable lockpin.
99. 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.
100. As a post-check, verify correct alignment of all timing marks.
     • There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
     • There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
101. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (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.
102. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (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.
103. Remove the RH Camshaft Holding Tool.
104. 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.
105. Remove the LH Camshaft Holding Tool.
106. 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.
107. NOTE: Use Spindle Bearing Installer 205-149 to install the seal.

     Using the Spindle Bearing Installer, install the front cover radial seal from the rear side of the front cover.

108. 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 1, 2, 7, 8, 16, 17, 18, 19, 20 and 21 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket 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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

     Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 2 engine front cover bolt bosses.

     • Apply a 5.5 mm (0.21 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.
109. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

     Install the engine front cover and bolts 1, 2, 7, 8, 16, 17, 18, 19, 20 and 21.

     • Tighten in sequence to 3 Nm (27 lb-in).
       Fig 52: Identifying Engine Front Cover And Bolts

       Courtesy of FORD MOTOR CO.
110. Install the remaining 18 engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in illustration in 4 stages:
     • Stage 1: Tighten bolts 1 through 21 to 10 Nm (89 lb-in).
     • Stage 2: Tighten bolts 1 through 20 to 24 Nm (18 lb-ft).
     • Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees.
     • Stage 4: Tighten bolt 22 to 10 Nm (89 lb-in) then an additional 45 degrees.
       Fig 53: Identifying Engine Front Cover Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
111. Using a new gasket, install the oil filter adapter and the 5 bolts and tighten in sequence shown in illustration.
     • Tighten to 10 Nm (89 lb-in) and then an additional 45 degrees.
       Fig 54: Identifying Oil Filter Adapter Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
112. Install the Crankshaft Position (CKP) sensor and install the bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 55: Locating CKP Sensor And Bolt

       Courtesy of FORD MOTOR CO.
113. Install the 2 RH Camshaft Position (CMP) sensors and the bolts.
     • Tighten to 10 Nm (89 lb-in).
114. Install the 2 LH CMP sensors and the bolts.
     • Tighten to 10 Nm (89 lb-in).
115. Install 6 new RH exhaust manifold studs.
     • Tighten to 12 Nm (106 lb-in).
       Fig 56: Locating RH Exhaust Manifold Studs

       Courtesy of FORD MOTOR CO.
116. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

     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 19 Nm (168 lb-in).
     • Stage 2: Tighten to 25 Nm (18 lb-ft).
       Fig 57: Identifying Exhaust Manifold Nuts Tightening Sequence

       Courtesy of FORD MOTOR CO.
117. Install the RH exhaust manifold heat shield and the 2 bolts.
     • Tighten to 10 Nm (89 lb-in).
118. NOTE: Installation of new seals is only required if damaged seals were removed.

     Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.

119. NOTE: Installation of new seals is only required if damaged seals were removed.

     Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).

120. NOTE: Failure to use the correct 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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

     Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

121. Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts in the sequence shown in illustration.
     • Tighten to 10 Nm (89 lb-in).
       Fig 58: Identifying RH Valve Cover Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
122. Ensure 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.
123. NOTE: Only use hand tools when installing the spark plugs, or damage may occur to the cylinder head or spark plug.

     Install the 3 RH spark plugs.

     • Tighten to 15 Nm (133 lb-in).
124. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
     • To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
       Fig 59: Locating Damaged Coil Seals

       Courtesy of FORD MOTOR CO.
125. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts.
     • Tighten to 7 Nm (62 lb-in).
126. Install 6 new LH exhaust manifold studs.
     • Tighten to 12 Nm (106 lb-in).
       Fig 60: Locating LH Exhaust Manifold Studs

       Courtesy of FORD MOTOR CO.
127. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

     Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration:

     • Stage 1: Tighten to 19 Nm (168 lb-in).
     • Stage 2: Tighten to 25 Nm (18 lb-ft).
       Fig 61: Identifying Exhaust Manifold Nuts Tightening Sequence

       Courtesy of FORD MOTOR CO.
128. Install the LH exhaust manifold heat shield and the 2 bolts.
     • Tighten to 10 Nm (89 lb-in).
129. NOTE: Installation of new seals is only required if damaged seals were removed.

     Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.

130. NOTE: Installation of new seals is only required if damaged seals were removed.

     Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).

131. NOTE: Failure to use the correct 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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

     Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

132. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts in the sequence shown in illustration.
     • Tighten to 10 Nm (89 lb-in).
       Fig 62: Identifying LH Valve Cover Bolts And Stud Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
133. Ensure 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.
134. NOTE: Only use hand tools when installing the spark plugs, or damage may occur to the cylinder head or spark plug.

     Install the 3 LH spark plugs.

     • Tighten to 15 Nm (133 lb-in).
135. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
     • To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
       Fig 63: Locating Damaged Coil Seals

       Courtesy of FORD MOTOR CO.
136. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts.
     • Tighten to 7 Nm (62 lb-in).
137. NOTE: Lubricate the O-ring seal with clean engine coolant.

     Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7 bolts and 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 64: Identifying Coolant Pump Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
138. Install the coolant pump pulley and the 4 bolts.
     • Tighten to 24 Nm (18 lb-ft).
139. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.

     Install the thermostat housing and the 4 bolts and tighten in the sequence shown in illustration in 2 stages.

     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 45 degrees.
       Fig 65: Identifying Thermostat Housing Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
140. Attach the heater tube retainer to the RH valve cover stud bolt.
141. Install the heater tube bolt.
     • Tighten to 23 Nm (17 lb-ft).
142. Install the RH cylinder block drain plug.
     • Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
       Fig 66: Locating LH Cylinder Block Drain Plug

       Courtesy of FORD MOTOR CO.
143. Install the LH cylinder block drain plug or, if equipped, the block heater.
     • Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
     • Tighten the block heater to 40 Nm (30 lb-ft).
       Fig 67: Locating RH Cylinder Block Drain Plug And Block Heater

       Courtesy of FORD MOTOR CO.
144. Install the accessory drive belt tensioner and the 2 bolts.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 68: Locating Accessory Drive Belt Tensioner And Bolts

       Courtesy of FORD MOTOR CO.
145. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

     Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.

     Fig 69: Installing Crankshaft Front Seal Using Front Crankshaft Seal Installer And Crankshaft Vibration Damper Installer

     Courtesy of FORD MOTOR CO.
146. Lubricate the crankshaft front seal inner lip with clean engine oil.
147. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

     Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.

     Fig 70: Installing Crankshaft Pulley Using Front Cover Oil Seal Installer And Crankshaft Vibration Damper Replacer

     Courtesy of FORD MOTOR CO.
148. Using the Strap Wrench, 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 71: Installing Crankshaft Pulley Washer And Bolt Using Strap Wrench

       Courtesy of FORD MOTOR CO.
149. Install the generator stud and position the generator and install the nut and bolt.
     • Tighten the stud to 8 Nm (71 lb-in).
     • Tighten the nut and bolt to 48 Nm (35 lb-ft).
150. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
151. Connect the CKP sensor electrical connector.
     Fig 72: Locating Crankshaft Position (CKP) Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
152. Install the wiring harness grommet.
     Fig 73: Locating Oil Pump And Bolts

     Courtesy of FORD MOTOR CO.
153. Install the wiring harness retainer stud bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 74: Locating Wiring Harness Retainer Stud Bolt

       Courtesy of FORD MOTOR CO.
154. Install the heat shield, the nut and the bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 75: Locating Nut, Bolt And Heat Shield

       Courtesy of FORD MOTOR CO.
155. Connect the 2 LH CMP sensors electrical connectors.
     • Attach the wiring harness retainer to the rear of the cylinder head.
156. Connect the KS sensor electrical connector.
157. Connect the 2 LH VCT solenoid electrical connectors.
158. Connect the 3 LH fuel rail electrical connectors.
159. Connect the 3 LH ignition coil-on-plug electrical connectors.
160. Connect the Engine Oil Pressure (EOP) switch electrical connector.
     • Attach the EOP switch wiring harness retainer to the cylinder head.
161. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
162. Connect the 2 RH CMP sensors electrical connectors.
163. Connect the 2 RH VCT solenoid electrical connectors.
164. Connect the 3 RH fuel rail electrical connectors.
165. Connect the CHT sensor wiring harness jumper electrical connector.
166. Connect the 3 RH ignition coil-on-plug electrical connectors.
167. Install the RH fuel rail insulator.
168. 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 gaskets, install the upper intake manifold and tighten the 7 bolts 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 76: Identifying Upper Intake Manifold Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
169. Install the upper intake manifold support bracket bolt to the RH cylinder head.
     • Tighten to 10 Nm (89 lb-in).
170. Install the LH fuel rail insulator.
171. Attach the wiring harness pin-type retainer to the rear of the upper intake manifold.
172. Connect the PCV tube quick connect couplings to the PCV valve and intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
173. Connect the Throttle Body (TB) electrical connector.
     • Attach the TB electrical connector wiring harness pin-type retainer to the TB.
174. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
     • Attach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
175. Install the engine oil level indicator.
176. Install the crankcase vent tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
177. Install the LH engine lift eye.
178. Install the RH front lift eye.
179. Using the Floor Crane and Spreader Bar, remove the engine from the stand.
     Fig 77: Mounting/Removing Engine Using Floor Crane And Spreader Bar

     Courtesy of FORD MOTOR CO.

     Cast aluminum (early build) crankshaft rear seal retainer plate 

180. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

     Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.

181. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.

     All engines 

182. Install the crankshaft sensor ring.
     Fig 78: Locating Crankshaft Sensor Ring

     Courtesy of FORD MOTOR CO.
183. NOTE: Flexplate shown in illustration, flywheel similar.

     Install the spacer plate.

     Fig 79: Locating Spacer Plate

     Courtesy of FORD MOTOR CO.

     Engines with manual transmission 

184. NOTE: The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).

     Install the flywheel and the 8 bolts and tighten is sequence shown in illustration.

     • Tighten to 80 Nm (59 lb-ft).
       Fig 80: Identifying Dual Mass Flywheel Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
185. NOTE: If installing the original pressure plate, align it using the index marks made during removal.
     NOTE: Always install new pressure plate bolts.

     Using a suitable clutch aligner, position the clutch disc on the flywheel, install the pressure plate and 6 new pressure plate bolts. Turn the bolts 1-2 turns at a time in a star pattern until the clutch is fully secured.

     • Tighten the pressure plate bolts in 2 stages in a star pattern
       • Stage 1: Tighten to 47 Nm (35 lb-ft).
       • Stage 2: Tighten an additional 60 degrees.
         Fig 81: Identifying Pressure Plate Bolts Tightening Sequence

         Courtesy of FORD MOTOR CO.

     Engines with automatic transmission 

186. Install the flexplate and the 8 bolts and tighten is sequence shown in illustration.
     • Tighten to 80 Nm (59 lb-ft).
       Fig 82: Identifying Flexplate Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.