Cylinder Head

	Compressor, Valve Spring 303-452 (T93P-6565-AR)
	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Holding Tool, Crankshaft 303-448 (T93P-6303-A)
	Installer, Crankshaft Front Oil Seal 303-635
	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
	Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
	Lifting Bracket, Engine (2 required) 303-D087 (D93P-6001-A1) or equivalent
	Lifting Bracket, Engine 303-D089 (D93P-6001-A3) or equivalent
	Strap Wrench 303-D055 (D85L-6000-A) or equivalent

Both cylinder heads 

1. NOTE: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. Failure to follow these instructions may result in engine damage. For additional information, refer to CYLINDER HEAD  .
   NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.
   NOTE: The new gasket has a film coating which is crucial to the ability of the gasket to seal correctly. Do not scratch the gasket.
   NOTE: RH head gasket shown in illustration, LH head gasket similar.

   Install the head gasket over the dowel pins.

   Fig 1: Installing Head Gasket Over Dowel Pins

   Courtesy of FORD MOTOR CO.
2. NOTE: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area. Failure to follow these instructions may result in engine damage.
   NOTE: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
   NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.
   NOTE: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation. Failure to follow these instructions may result in engine damage.
   NOTE: LH shown in illustration, RH similar.

   Install the cylinder head on the dowels and the head gasket.

   • Loosely install the new bolts.
     Fig 2: Locating Cylinder Head Bolts

     Courtesy of FORD MOTOR CO.

   RH cylinder head 

3. Tighten the new cylinder head bolts in the sequence shown in illustration in 5 stages.
   • Stage 1: Tighten to 20 Nm (177 lb-in).
   • Stage 2: Tighten to 50 Nm (37 lb-ft).
   • Stage 3: Tighten an additional 90 degrees.
   • Stage 4: Tighten an additional 90 degrees.
   • Stage 5: Tighten an additional 90 degrees.
     Fig 3: Identifying RH Cylinder Head Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
4. Install the 3 coolant tube assembly bolts.
   • Tighten 10 Nm (89 lb-in).
     Fig 4: Locating Coolant Tube Assembly Bolts

     Courtesy of FORD MOTOR CO.
5. NOTE: Hand start the studs first.

   Install 8 new RH exhaust manifold studs.

   • Tighten to 12 Nm (106 lb-in).
     Fig 5: Locating RH Exhaust Manifold Studs

     Courtesy of FORD MOTOR CO.
6. Install new RH exhaust manifold gaskets, the RH exhaust manifold and 8 new nuts. Tighten in the sequence shown in illustration.
   • Tighten to 20 Nm (177 lb-in).

   LH cylinder head 

7. Tighten the new cylinder head bolts in the sequence shown in illustration in 5 stages.
   • Stage 1: Tighten to 20 Nm (177 lb-in).
   • Stage 2: Tighten to 50 Nm (37 lb-ft).
   • Stage 3: Tighten an additional 90 degrees.
   • Stage 4: Tighten an additional 90 degrees.
   • Stage 5: Tighten an additional 90 degrees.
     Fig 6: Identifying LH Cylinder Head Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
8. NOTE: Hand start the studs first.

   Install 8 new LH exhaust manifold studs.

   • Tighten to 12 Nm (106 lb-in).
     Fig 7: Locating LH Exhaust Manifold Studs

     Courtesy of FORD MOTOR CO.
9. Install new LH exhaust manifold gaskets, the LH exhaust manifold and 8 new nuts. Tighten in the sequence shown in illustration.
   • Tighten to 20 Nm (177 lb-in).
10. Connect the 2 LH Heated Oxygen Sensor (HO2S) wire retainers.

    Both cylinder heads 

11. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    NOTE: LH shown in illustration, RH similar.

    Compress each tensioner plunger, using an edge of a vise.

    Fig 8: Compressing Tensioner Plunger Using Vise

    Courtesy of FORD MOTOR CO.
12. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
    Fig 9: Holding Ratchet Mechanism Using Screwdriver

    Courtesy of FORD MOTOR CO.
13. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 10: Pushing Ratchet Arm Back Into Tensioner Housing

    Courtesy of FORD MOTOR CO.
14. Install a suitable pin into the hole of each tensioner housing to hold the ratchet assembly and plunger in place during installation.
    • Remove the tensioner from the vise.
      Fig 11: Installing Paper Clip Into Hole Of Tensioner Housing

      Courtesy of FORD MOTOR CO.
15. If the colored links are not visible, mark one link on one end and 2 links on the other end, and use as timing marks.
    Fig 12: Locating Copper Link Timing Marks

    Courtesy of FORD MOTOR CO.
16. Using the Crankshaft Holding Tool, position the crankshaft.
    Fig 13: Positioning Crankshaft Using Crankshaft Holding Tool

    Courtesy of FORD MOTOR CO.
17. Install the crankshaft sprocket with the flange facing forward.
    Fig 14: Locating Crankshaft Sprocket Flange Facing

    Courtesy of FORD MOTOR CO.
18. Install the LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 15: Locating LH Primary Timing Chain Guide And Bolts

      Courtesy of FORD MOTOR CO.
19. Position the camshaft sprocket timing marks as shown in illustration.
    Fig 16: Locating Camshaft Sprocket Timing Marks

    Courtesy of FORD MOTOR CO.
20. Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one colored link on the timing chain with the slot on the crankshaft sprocket.
    Fig 17: Locating Crankshaft Sprocket Timing Mark Aligning Position

    Courtesy of FORD MOTOR CO.
21. Install the LH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.
    Fig 18: Locating Timing Marks On Timing Chain

    Courtesy of FORD MOTOR CO.
22. Install the LH primary timing chain tensioner arm.
    Fig 19: Locating LH Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
23. Install the LH primary timing chain tensioner and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Remove the pin from the tensioner.
      Fig 20: Locating LH Primary Timing Chain Tensioner And Bolts

      Courtesy of FORD MOTOR CO.
24. Install the RH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 21: Locating RH Primary Timing Chain Guide And Bolts

      Courtesy of FORD MOTOR CO.
25. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored link with the timing marks on the sprocket.
    Fig 22: Locating Copper (Marked) Link With Timing Mark On Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
26. Install the RH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.
    Fig 23: Locating RH Timing Chain Timing Mark On Camshaft Sprocket

    Courtesy of FORD MOTOR CO.
27. Install the RH primary timing chain tensioner arm.
    Fig 24: Locating RH Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
28. Install the RH primary timing chain tensioner and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Remove the pin from the tensioner.
      Fig 25: Locating RH Primary Timing Chain Tensioner And Bolts

      Courtesy of FORD MOTOR CO.
29. As a post-check, verify correct alignment of all timing marks. Make sure that the colored links are lined up with the marks on the crankshaft sprocket and the camshaft sprockets.
    Fig 26: Locating Timing Marks On Crankshaft Sprocket And Camshaft Sprockets

    Courtesy of FORD MOTOR CO.
30. Install the crankshaft washer.
    Fig 27: Locating Crankshaft Washer

    Courtesy of FORD MOTOR CO.
31. Install the crankshaft sensor ring.
    Fig 28: Locating Crankshaft Sensor Ring

    Courtesy of FORD MOTOR CO.
32. NOTE: If the components are to be reinstalled, they must be installed in their original positions or damage to the engine may occur.

    Install the hydraulic lash adjusters.

    Fig 29: Locating Hydraulic Lash Adjusters

    Courtesy of FORD MOTOR CO.
33. Using the Valve Spring Compressor, compress the valve spring and install the roller follower.
    Fig 30: Compressing Valve Spring Using Special Tool

    Courtesy of FORD MOTOR CO.
34. Repeat the previous step to install all the roller followers.
35. NOTE: Only use hand tools when removing or installing the spark plugs, or damage may occur to the cylinder head or spark plugs.
    NOTE: RH shown in illustration, LH similar.

    Install the 8 spark plugs.

    • Tighten to 18 Nm (159 lb-in).
      Fig 31: Locating Spark Plugs

      Courtesy of FORD MOTOR CO.
36. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.

    Apply Motorcraft® High Performance Engine RTV Silicone in the locations shown in illustration.

    Fig 32: Locating Bead Of Motorcraft® High Performance Engine RTV Silicone Applying Area

    Courtesy of FORD MOTOR CO.
37. Using new gaskets, install the engine front cover and the 16 bolts. Tighten the bolts in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten bolts 1 through 14 to 25 Nm (18 lb-ft).
    • Stage 2: Tighten bolts 15 and 16 to 48 Nm (35 lb-ft).

      Item	Part Number	Description
      1	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      2	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      3	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      4	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      5	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      6	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      7	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      8	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      9	N808586	Stud bolt, hex head pilot, M8 x 1.25 x 50
      10	N808586	Stud bolt, hex head pilot, M8 x 1.25 x 50
      11	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      12	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      13	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      14	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
      15	N606063	Bolt, hex flange head pilot, M10 x 1.50 x 55
      16	N606063	Bolt, hex flange head pilot, M10 x 1.50 x 55

38. Install the oil pan-to-engine front cover bolt and the 3 oil pan-to-engine front cover stud bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 33: Locating Oil Pan-To-Engine Front Cover Stud Bolts

      Courtesy of FORD MOTOR CO.
39. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 34: Locating Engine Front Cover And Crankshaft Front Seal Inner Lip

    Courtesy of FORD MOTOR CO.
40. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and the Crankshaft Front Oil Seal Installer, install the crankshaft front seal.
    Fig 35: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tools

    Courtesy of FORD MOTOR CO.
41. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

    Apply Motorcraft® High Performance Engine RTV Silicone to the Woodruff key slot on the crankshaft pulley.

    Fig 36: Locating Motorcraft® High Performance Engine RTV Silicone Applying Area On Woodruff Key Slot

    Courtesy of FORD MOTOR CO.
42. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
    Fig 37: Locating Crankshaft Pulley Sealing Surface

    Courtesy of FORD MOTOR CO.
43. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
    Fig 38: Installing Crankshaft Pulley Using Crankshaft Vibration Damper Installer

    Courtesy of FORD MOTOR CO.
44. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer. Tighten the bolt in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 40 Nm (30 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
      Fig 39: Removing/Installing Crankshaft Pulley Bolt And Washer Using Strap Wrench

      Courtesy of FORD MOTOR CO.
45. Install the coolant pump and the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 40: Locating Coolant Pump Bolts

      Courtesy of FORD MOTOR CO.
46. Install the Camshaft Position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 41: Locating Camshaft Position (CMP) Sensor And Bolt

      Courtesy of FORD MOTOR CO.
47. Install the Crankshaft Position (CKP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 42: Locating Crankshaft Position (CKP) Sensor And Bolt

      Courtesy of FORD MOTOR CO.
48. Install new gaskets. Make sure the gaskets are correctly seated on the valve cover.
    Fig 43: Locating Valve Cover Mating Surfaces And Gaskets

    Courtesy of FORD MOTOR CO.
49. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    NOTE: LH shown in illustration, RH similar.

    Apply Motorcraft® High Performance Engine RTV Silicone in the locations shown in illustration.

    Fig 44: Locating Bead Of Motorcraft® High Performance Engine RTV Silicone Applying Area

    Courtesy of FORD MOTOR CO.
50. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

    Install the RH valve cover and the 10 bolts. Tighten in the sequence shown in illustration.

    • Tighten to 10 Nm (89 lb-in).
      Fig 45: Identifying RH Valve Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
51. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

    Install the LH valve cover and the 10 bolts. Tighten in the sequence shown in illustration.

    • Tighten to 10 Nm (89 lb-in).
      Fig 46: Identifying LH Valve Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
52. NOTE: LH shown in illustration, RH similar.

    If equipped, install the LH and RH block drain plugs.

    • Tighten to 14 Nm (124 lb-in).
      Fig 47: Locating Block Drain Plug

      Courtesy of FORD MOTOR CO.
53. Install the RH engine insulator bracket, the stud bolt, and the 3 bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 48: Locating RH Engine Support Insulator Bracket And Bolts

      Courtesy of FORD MOTOR CO.
54. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation.

    Using a new O-ring seal, install the oil level indicator tube, bolt and oil level indicator.

    • Tighten to 10 Nm (89 lb-in).
      Fig 49: Locating Oil Level Indicator Tube And Bolt

      Courtesy of FORD MOTOR CO.
55. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

    Using a new gasket, install the oil filter adapter and the 8 bolts. Tighten in the sequence shown in illustration in 2 stages.

    • Stage 1: Bolts 1 through 6 to 25 Nm (18 lb-ft).
    • Stage 2: Bolts 7 and 8 to 48 Nm (35 lb-ft).
      Fig 50: Identifying Oil Filter Adapter Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
56. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
    NOTE: Oil cooler shown in illustration, oil cooler thermostat similar.

    Using a new gasket, install the oil cooler and the 6 bolts. Tighten in the sequence shown in illustration in 2 stages.

    • Stage 1: Tighten to 9 Nm (80 lb-in).
    • Stage 2: Tighten an additional 60 degrees.
      Fig 51: Identifying Oil Cooler Thermostat Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
57. Install the 3 coolant tube assembly bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 52: Locating Coolant Tube Assembly Bolts

      Courtesy of FORD MOTOR CO.
58. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

    Using new intake manifold gaskets, install the intake manifold and the 14 bolts. Tighten in the sequence shown in illustration.

    • Tighten to 10 Nm (89 lb-in).
59. Connect the intake manifold-to-coolant tube assembly hose.
    Fig 53: Locating Intake Manifold-To-Coolant Tube Assembly Hose Clamp

    Courtesy of FORD MOTOR CO.
60. Position the wiring harness assembly onto the engine.
61. NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation.

    Install the 4 LH coil-on-plugs.

    • Connect the 4 LH coil-on-plug electrical connectors.
      Fig 54: Locating LH Coil-On-Plug Electrical Connectors

      Courtesy of FORD MOTOR CO.
62. Install the LH coil-on-plug cover and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 55: Locating LH Coil-On-Plug Cover Bolts

      Courtesy of FORD MOTOR CO.
63. Attach the wiring harness retainers to the LH valve cover stud bolts.
    Fig 56: Locating Wiring Harness Retainers On LH Valve Cover Stud Bolts

    Courtesy of FORD MOTOR CO.
64. Position the LH radio interference capacitor and install the nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 57: Locating LH Radio Interference Capacitor And Nut

      Courtesy of FORD MOTOR CO.
65. Connect the 4 LH fuel injector electrical connectors.
    Fig 58: Locating LH Fuel Injector Electrical Connectors

    Courtesy of FORD MOTOR CO.
66. Connect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
    Fig 59: Locating Intake Air Temperature 2 (IAT2) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
67. Connect the CMP sensor electrical connector.
    Fig 60: Locating Camshaft Position (CMP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
68. NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation.

    Install the 4 RH coil-on-plugs.

    • Connect the 4 RH coil-on-plug electrical connectors.
      Fig 61: Locating RH Coil-On-Plug Electrical Connectors

      Courtesy of FORD MOTOR CO.
69. Install the RH coil-on-plug cover and 2 stud bolts.
    • Tighten to 10 Nm (89 lb-in).
70. Install the A/C tube support bracket and nut.
    • Tighten to 9 Nm (80 lb-in).
      Fig 62: Locating A/C Tube Support Bracket And Nut

      Courtesy of FORD MOTOR CO.
71. Attach the wiring harness retainers to the RH valve cover stud bolts.
    Fig 63: Locating Wiring Harness Retainers On RH Valve Cover Stud Bolts

    Courtesy of FORD MOTOR CO.
72. Attach the wiring harness retainers to the RH coil-on-plug cover stud bolts.
73. Connect the EGR valve electrical connector.
    Fig 64: Locating EGR Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
74. Position the RH radio interference capacitor and install the nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 65: Locating RH Radio Interference Capacitor And Nut

      Courtesy of FORD MOTOR CO.
75. Connect the fuel rail pressure and temperature sensor electrical connector.
    Fig 66: Locating Fuel Rail Pressure And Temperature Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
76. Connect the 4 RH fuel injector electrical connectors.
    Fig 67: Locating RH Fuel Injector Electrical Connectors

    Courtesy of FORD MOTOR CO.
77. Connect the PCV valve electrical connector.
    Fig 68: Locating PCV Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
78. Attach the 2 wiring harness pin-type retainers.
    Fig 69: Locating Wiring Harness Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
79. Install the wiring harness retaining bracket and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 70: Locating Wiring Harness Retaining Bracket And Bolts

      Courtesy of FORD MOTOR CO.
80. Connect the bubbler hose to the Supercharger (SC).
    Fig 71: Locating Bubbler Hose Clamp

    Courtesy of FORD MOTOR CO.
81. Attach the 2 wiring harness pin-type retainers (1 shown in illustration) to the coolant tube assembly bracket.
    Fig 72: Locating Wiring Harness Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
82. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 73: Locating Cylinder Head Temperature Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
83. Install a new gasket, the Throttle Body (TB) and spacer assembly and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 74: Locating Throttle Body And Spacer Assembly Bolts

      Courtesy of FORD MOTOR CO.
84. Connect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.
    Fig 75: Locating Throttle Position Sensor And Electronic Throttle Control Electrical Connectors

    Courtesy of FORD MOTOR CO.
85. Connect the EVAP Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 76: Locating Evaporative Emission Canister Purge Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
86. Install and connect the crankcase ventilation tube.
87. NOTE: Hand start the top fitting first.

    Install the EGR tube.

    • Tighten to 43 Nm (32 lb-ft).
      Fig 77: Locating EGR Tube Fittings And EGR Tube

      Courtesy of FORD MOTOR CO.
88. Install the 3 SC drive belt idler pulleys and the 3 bolts.
    • Tighten the heavy load idler pulley (closest to centerline of engine) to 48 Nm (35 lb-ft).
    • Tighten the smooth idler pulley and the grooved idler pulley to 25 Nm (18 lb-ft).
      Fig 78: Locating SC Drive Belt Idler Pulleys And Bolts

      Courtesy of FORD MOTOR CO.
89. Using the Strap Wrench, install the coolant pump pulley and the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 79: Locating Coolant Pump Pulley And Bolts

      Courtesy of FORD MOTOR CO.
90. Install the accessory drive belt idler pulley (grooved) and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 80: Locating Bolt And Accessory Drive Belt Idler Pulley (Grooved)

      Courtesy of FORD MOTOR CO.
91. Install the accessory drive belt idler pulley (smooth) and the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 81: Locating Stud Bolt And Accessory Drive Belt Idler Pulley (Smooth)

      Courtesy of FORD MOTOR CO.
92. Install the accessory drive belt idler pulley and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 82: Locating Accessory Drive Belt Idler Pulley Bolts

      Courtesy of FORD MOTOR CO.
93. Install the accessory drive belt tensioner and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 83: Locating Accessory Drive Belt Tensioner And Bolt

      Courtesy of FORD MOTOR CO.
94. Install the alternator and the 3 bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 84: Locating Alternator Bolts

      Courtesy of FORD MOTOR CO.
95. Connect the coolant hose from the Charge Air Cooler (CAC).
    Fig 85: Locating Coolant Hose Clamp

    Courtesy of FORD MOTOR CO.
96. Install the thermostat housing assembly and the 2 nuts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 86: Locating Thermostat Housing Assembly Nuts

      Courtesy of FORD MOTOR CO.
97. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
    Fig 87: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
98. Connect the 2 upper radiator hoses to the intake manifold.
    Fig 88: Locating Upper Radiator Hoses Clamps

    Courtesy of FORD MOTOR CO.
99. Install the engine vent hose to the intake manifold.
100. If equipped, install the coolant tube and the coolant tube bracket nut.
     • Tighten to 9 Nm (80 lb-in).
       Fig 89: Locating Coolant Tube Bracket And Nut

       Courtesy of FORD MOTOR CO.
101. If equipped, connect the coolant hose to the thermostat housing.
     Fig 90: Locating Thermostat Housing Coolant Hose

     Courtesy of FORD MOTOR CO.
102. If equipped, connect the coolant hose to the oil cooler.
103. Install the Engine Lifting Bracket.
     Fig 91: Installing Engine Lifting Bracket

     Courtesy of FORD MOTOR CO.
104. Install the Engine Lifting Bracket.
     Fig 92: Installing Engine Lifting Bracket

     Courtesy of FORD MOTOR CO.
105. Using the Floor Crane and the Engine Lifting Bracket, remove the engine from the work stand.
     Fig 93: Removing Engine From Work Stand Using Floor Crane And Engine Lifting Bracket

     Courtesy of FORD MOTOR CO.
106. Install the engine/transmission spacer plate.
     Fig 94: Locating Engine-To-Transmission Spacer Plate

     Courtesy of FORD MOTOR CO.
107. Tighten the flywheel bolts evenly in the sequence shown in illustration to fully seat the flywheel on the crankshaft pilot.
     • Tighten to 80 Nm (59 lb-ft).
       Fig 95: Identifying Flywheel Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
108. Install the engine into the vehicle, refer to ENGINE .