Flywheel and Exhaust Manifolds

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Flywheel And Exhaust Manifolds Components

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	9D477	EGR tube
2	9428	RH exhaust manifold
3	9Y431	RH exhaust manifold gasket (2 required)
4	6375	Flywheel
5	6A373	Engine-to-transmission spacer plate
6	6310	Crankshaft oil slinger
7	6701	Crankshaft rear seal
8	6K318	Crankshaft rear seal retainer plate
9	18C553	Coolant tube assembly
10	9431	LH exhaust manifold
11	9Y431	LH exhaust manifold gasket (2 required)
12	6754	Oil level indicator tube assembly

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play. Refer to ENGINE SYSTEM - GENERAL INFORMATION .

Install the 8 oil squirters.
- Tighten to 4 Nm (35 lb-in).
  
  Fig 2: Locating Oil Squirters
  Courtesy of FORD MOTOR CO.
Record the first character code information on the cylinder block.

Fig 3: Locating Character Code Information Label On Cylinder Block
Courtesy of FORD MOTOR CO.
Note the first character on the No. 7 crankshaft counterweight.

Fig 4: Locating Main Bearing Code On Crankshaft Counter Weight
Courtesy of FORD MOTOR CO.
Using the data recorded in the previous 2 steps, cross-reference using the chart to obtain bearing grade.

Fig 5: Main Bearing Selection 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 into the cylinder block.
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.
NOTE: Make sure the side of the thrust washer, with three 5-mm 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. 5 main boss.

Fig 6: Installing Rear Crankshaft Upper Thrust Washer
Courtesy of FORD MOTOR CO.
NOTE: Make sure the side of the thrust washer, with three 5-mm 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. 5 main boss.

Fig 7: Installing Front Upper Crankshaft Thrust Washer
Courtesy of FORD MOTOR CO.
NOTE: Make sure the side of the thrust washer, with three 5-mm 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. 5 main bearing cap, with the tab aligned with the cutout in the main bearing cap.

Fig 8: Locating Lower Crankshaft Thrust Washer Tab And Main Bearing Cap Cutout
Courtesy of FORD MOTOR CO.
Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new cap fasteners.
Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.

Fig 9: Installing Crankshaft Lower Main Bearings
Courtesy of FORD MOTOR CO.
Install 30 new crankshaft main bearing cap fasteners hand tight.

Fig 10: Locating Crankshaft Main Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
Tighten the 10 new outside vertical main bearing cap fasteners in the sequence shown in illustration in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 40 Nm (30 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 11: Identifying Outside Vertical Main Bearing Cap Fasteners Tightening Sequence
  Courtesy of FORD MOTOR CO.
Tighten the 10 new inside vertical main bearing cap fasteners in the sequence shown in illustration in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 40 Nm (30 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 12: Identifying Inside Vertical Main Bearing Cap Fasteners Tightening Sequence
  Courtesy of FORD MOTOR CO.
Tighten the 10 new side bolts in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 13: Identifying Side Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
Check the crankshaft end play. Refer to ENGINE SYSTEM - GENERAL INFORMATION .
NOTE: Verify correct orientation of connecting rod and rod cap.

Prepare the connecting rod and cap.
- Insert the bolts in the rod cap.
- Insert the upper and lower rod bearings into the rod and cap.
  
  Fig 14: Installing Lower Bearing And Connecting Rod Cap Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown in illustration.

NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.

Using the Piston Ring Compressor and the Connecting Rod Installer, install the No. 1 and No. 6 piston and the connecting rod assemblies.
- Lubricate the piston and rings with clean engine oil.
- Lubricate the rod bearings with clean engine oil.
- Lubricate the cylinder bores with clean engine oil.
  
  Fig 15: Installing No. 1 And No. 6 Piston
  Courtesy of FORD MOTOR CO.
Seat the connecting rods on the crankshaft journals and remove the Connecting Rod Installer.

Fig 16: Seating Connecting Rods On Crankshaft Journals
Courtesy of FORD MOTOR CO.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or damage to the engine may occur.

NOTE: Rotate the crankshaft after each connecting rod is installed and tightened, to check for assembly binding.

Install the rod bearing caps and the rob bearing cap bolts. Tighten the bolts in 3 stages.
- Stage 1: Tighten to 25 Nm (30 lb-ft).
- Stage 2: Tighten to 33 Nm (30 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 17: Locating Rob Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Install the piston assemblies 3 and 5, 4 and 7, 2 and 8, by turning the crankshaft 90 degrees and repeating the previous steps.
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 RH and LH head gasket over the dowel pins.

Fig 18: Installing Head Gasket Over Dowel Pins
Courtesy of FORD MOTOR CO.
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 RH and LH cylinder heads on the dowels and the head gaskets.
- Loosely install new bolts.
  
  Fig 19: Locating Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.
Tighten the new RH 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 20: Identifying RH Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Tighten the new LH 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 21: Identifying LH Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the oil pump and 3 bolts. Tighten in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 22: Identifying Oil Pump Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
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 23: Compressing Tensioner Plunger Using Vise
Courtesy of FORD MOTOR CO.
Using a small screwdriver or pick, push back and hold the ratchet mechanism.

Fig 24: Holding Ratchet Mechanism Using Screwdriver
Courtesy of FORD MOTOR CO.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 25: Pushing Ratchet Arm Back Into Tensioner Housing
Courtesy of FORD MOTOR CO.
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 26: Installing Paper Clip Into Hole Of Tensioner Housing
  Courtesy of FORD MOTOR CO.
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 27: Locating Copper Link Timing Marks
Courtesy of FORD MOTOR CO.
Using the Crankshaft Holding Tool, position the crankshaft.

Fig 28: Positioning Crankshaft Using Crankshaft Holding Tool
Courtesy of FORD MOTOR CO.
Install the crankshaft sprocket with the flange facing forward.

Fig 29: Locating Crankshaft Sprocket Flange Facing
Courtesy of FORD MOTOR CO.
Position the camshaft sprocket timing marks as shown in illustration.

Fig 30: Locating Camshaft Sprocket Timing Marks
Courtesy of FORD MOTOR CO.
Install the LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 31: Locating LH Primary Timing Chain Guide And Bolts
  Courtesy of FORD MOTOR CO.
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 32: Locating Crankshaft Sprocket Timing Mark Aligning Position
Courtesy of FORD MOTOR CO.
Install the LH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.

Fig 33: Locating Timing Marks On Timing Chain
Courtesy of FORD MOTOR CO.
Install the LH primary timing chain tensioner arm.

Fig 34: Locating LH Primary Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
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 35: Locating LH Primary Timing Chain Tensioner And Bolts
  Courtesy of FORD MOTOR CO.
Install the RH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 36: Locating RH Primary Timing Chain Guide And Bolts
  Courtesy of FORD MOTOR CO.
Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored link with the timing marks on the sprocket.

Fig 37: Locating Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the RH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.

Fig 38: Locating RH Timing Chain Timing Mark On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the RH primary timing chain tensioner arm.

Fig 39: Locating RH Primary Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
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 40: Locating RH Primary Timing Chain Tensioner And Bolts
  Courtesy of FORD MOTOR CO.
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 41: Locating Timing Marks On Crankshaft Sprocket And Camshaft Sprockets
Courtesy of FORD MOTOR CO.
Install the crankshaft washer.

Fig 42: Locating Crankshaft Washer
Courtesy of FORD MOTOR CO.
Install the crankshaft sensor ring.

Fig 43: Locating Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
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 44: Locating Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.
Using the Valve Spring Compressor, compress the valve spring and install the roller follower.

Fig 45: Compressing Valve Spring Using Special Tool
Courtesy of FORD MOTOR CO.
Repeat the previous step to install all the roller followers.
NOTE: RH shown in illustration, LH similar.

Install the 8 spark plugs.
- Tighten to 18 Nm (159 lb-in).
  
  Fig 46: Locating Spark Plugs
  Courtesy of FORD MOTOR CO.
NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all 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 a bead of Motorcraft® High Performance Engine RTV Silicone to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.

Fig 47: Locating Bead Of Motorcraft® High Performance Engine RTV Silicone Applying Area
Courtesy of FORD MOTOR CO.

NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.

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

Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

Fig 48: Locating Engine Front Cover And Crankshaft Front Seal Inner Lip
Courtesy of FORD MOTOR CO.
Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and the Crankshaft Front Oil Seal Installer, install the crankshaft front seal.

Fig 49: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tools
Courtesy of FORD MOTOR CO.
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 50: Locating Motorcraft® High Performance Engine RTV Silicone Applying Area On Woodruff Key Slot
Courtesy of FORD MOTOR CO.
Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.

Fig 51: Locating Crankshaft Pulley Sealing Surface
Courtesy of FORD MOTOR CO.
Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

Fig 52: Installing Crankshaft Pulley Using Crankshaft Vibration Damper Installer
Courtesy of FORD MOTOR CO.
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 53: Removing/Installing Crankshaft Pulley Bolt And Washer Using Strap Wrench
  Courtesy of FORD MOTOR CO.
Install the coolant pump and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 54: Locating Coolant Pump Bolts
  Courtesy of FORD MOTOR CO.
Install the Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 55: Locating CMP Sensor And Bolt
  Courtesy of FORD MOTOR CO.
Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 56: Locating Crankshaft Position (CKP) Sensor And Bolt
  Courtesy of FORD MOTOR CO.
Install new gaskets. Make sure the gaskets are correctly seated on the valve cover.

Fig 57: Locating Valve Cover Mating Surfaces And Gaskets
Courtesy of FORD MOTOR CO.
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 to the engine front cover-to-cylinder block joints.

Fig 58: Locating Bead Of Motorcraft® High Performance Engine RTV Silicone Applying Area
Courtesy of FORD MOTOR CO.
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 59: Identifying RH Valve Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
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 60: Identifying LH Valve Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
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 61: Locating Block Drain Plug
  Courtesy of FORD MOTOR CO.
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: Tighten bolts 1 through 6 to 25 Nm (18 lb-ft).
- Stage 2: Tighten bolts 7 and 8 to 48 Nm (35 lb-ft).
  
  Fig 62: Identifying Oil Filter Adapter Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: A new oil cooler and oil cooler thermostat (if equipped) must be installed or severe damage to the engine can occur.

NOTE: Oil cooler shown in illustration, oil cooler thermostat similar.

Using new gaskets, install a new oil cooler or the oil cooler thermostat 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 63: Identifying Oil Cooler Thermostat Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the coolant tube assembly and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 64: Locating Coolant Tube Assembly Bolts
  Courtesy of FORD MOTOR CO.
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 65: Locating Oil Level Indicator Tube And Bolts
  Courtesy of FORD MOTOR CO.
Install the 3 coolant tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 66: Locating Coolant Tube Assembly Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Hand start the studs first.

Install 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 67: Locating LH Exhaust Manifold Studs
  Courtesy of FORD MOTOR CO.
Install new gaskets, the LH exhaust manifold and 8 new nuts. Tighten in the sequence shown in illustration.
- Tighten to 20 Nm (177 lb-in).
Connect the 2 LH Heated Oxygen Sensor (HO2S) wire retainers.
Install the LH engine support insulator bracket and the 4 bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 68: Locating LH Engine Mount Bracket And Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Hand start the studs first.

Install 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 69: Locating RH Exhaust Manifold Studs
  Courtesy of FORD MOTOR CO.
Install new gaskets, the RH exhaust manifold and 8 new nuts. Tighten in the sequence shown in illustration.
- Tighten to 20 Nm (177 lb-in).
Install the RH engine support insulator bracket, the 2 stud bolts, and the 2 bolts.
- Tighten to 55 Nm (41 lb-ft).
Install the Knock Sensor (KS) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 70: Locating Knock Sensor (KS) Bolts
  Courtesy of FORD MOTOR CO.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Clean and inspect 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).
Connect the intake manifold-to-coolant tube assembly hose.

Fig 71: Locating Intake Manifold-To-Coolant Tube Assembly Hose Clamp
Courtesy of FORD MOTOR CO.
Position the wiring harness assembly onto the engine.
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 72: Locating LH Coil-On-Plug Electrical Connectors
  Courtesy of FORD MOTOR CO.
Install the LH coil-on-plug cover and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
Attach the wiring harness retainers to the LH valve cover stud bolts.

Fig 73: Locating Wiring Harness Retainers On LH Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
Position the LH radio interference capacitor and install the nut.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 74: Locating LH Radio Interference Capacitor And Nut
  Courtesy of FORD MOTOR CO.
Connect the 4 LH fuel injector electrical connectors.

Fig 75: Locating LH Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the Intake Air Temperature 2 (IAT2) sensor electrical connector.

Fig 76: Locating Intake Air Temperature 2 (IAT2) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the CMP sensor electrical connector.

Fig 77: Locating Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
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 78: Locating RH Coil-On-Plug Electrical Connectors
  Courtesy of FORD MOTOR CO.
Install the RH coil-on-plug cover and 2 stud bolts.
- Tighten to 10 Nm (89 lb-in).
Install the A/C tube support bracket and the nut.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 79: Locating A/C Tube Support Bracket And Nut
  Courtesy of FORD MOTOR CO.
Attach the wiring harness retainers to the RH valve cover stud bolts.

Fig 80: Locating Wiring Harness Retainers On RH Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainers to the RH coil-on-plug cover stud bolts.
Connect the EGR valve electrical connector.

Fig 81: Locating EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Position the RH radio interference capacitor and install the nut.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 82: Locating RH Radio Interference Capacitor And Nut
  Courtesy of FORD MOTOR CO.
Connect the fuel rail pressure and temperature sensor electrical connector.

Fig 83: Locating Fuel Rail Pressure And Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 4 RH fuel injector electrical connectors.

Fig 84: Locating RH Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the PCV valve electrical connector.

Fig 85: Locating PCV Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Attach the 2 wiring harness pin-type retainers.

Fig 86: Locating Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Install the wiring harness retaining bracket and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 87: Locating Wiring Harness Retaining Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Connect the KS electrical connector.

Fig 88: Locating Knock Sensor (KS) Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Connect the bubbler hose to the Supercharger (SC).

Fig 89: Locating Bubbler Hose Clamp
Courtesy of FORD MOTOR CO.
Attach the 2 wiring harness pin-type retainers (1 shown in illustration) to the coolant tube assembly bracket.

Fig 90: Locating Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Connect the Cylinder Head Temperature (CHT) sensor electrical connector.

Fig 91: Locating Cylinder Head Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install a new gasket, the Throttle Body (TB) and spacer assembly and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 92: Locating Throttle Body And Spacer Assembly Bolts
  Courtesy of FORD MOTOR CO.
Connect the EVAP Evaporative Emission (EVAP) canister purge valve electrical connector.

Fig 93: Locating Evaporative Emission Canister Purge Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.

Fig 94: Locating Throttle Position Sensor And Electronic Throttle Control Electrical Connectors
Courtesy of FORD MOTOR CO.
Install and connect the crankcase ventilation tube.
Install the ground wire and the bolt to the rear of the LH cylinder head.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 95: Locating Rear Of LH Cylinder Head Ground Wire And Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Hand start the top fitting first.

Install the EGR tube.
- Tighten to 43 Nm (32 lb-ft).
  
  Fig 96: Locating EGR Tube Fittings And EGR Tube
  Courtesy of FORD MOTOR CO.
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 97: Locating SC Drive Belt Idler Pulleys And Bolts
  Courtesy of FORD MOTOR CO.
Using the Strap Wrench, install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 98: Locating Coolant Pump Pulley And Bolts
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley (grooved) and the bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 99: Locating Bolt And Accessory Drive Belt Idler Pulley (Grooved)
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley (smooth) and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 100: Locating Stud Bolt And Accessory Drive Belt Idler Pulley (Smooth)
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 101: Locating Accessory Drive Belt Idler Pulley Bolts
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt tensioner and the bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 102: Locating Accessory Drive Belt Tensioner And Bolt
  Courtesy of FORD MOTOR CO.
Install the generator and the 3 bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 103: Locating Alternator Bolts
  Courtesy of FORD MOTOR CO.
Connect the coolant hose to the Charge Air Cooler (CAC).

Fig 104: Locating Coolant Hose Clamp
Courtesy of FORD MOTOR CO.
Install the thermostat housing assembly and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 105: Locating Thermostat Housing Assembly Nuts
  Courtesy of FORD MOTOR CO.
Connect the Engine Coolant Temperature (ECT) sensor electrical connector.

Fig 106: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 2 upper radiator hoses to the intake manifold.

Fig 107: Locating Upper Radiator Hoses Clamps
Courtesy of FORD MOTOR CO.
Install the engine vent hose from the intake manifold.
If equipped, install the coolant tube and the coolant tube bracket nut.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 108: Locating Coolant Tube Bracket And Nut
  Courtesy of FORD MOTOR CO.
If equipped, connect the coolant hose to the thermostat housing.

Fig 109: Locating Thermostat Housing Coolant Hose
Courtesy of FORD MOTOR CO.
If equipped, connect the coolant hose to the oil cooler.
Install the Engine Lifting Bracket.

Fig 110: Installing Engine Lifting Bracket
Courtesy of FORD MOTOR CO.
Install the Engine Lifting Bracket.

Fig 111: Installing Engine Lifting Bracket
Courtesy of FORD MOTOR CO.
Using the Floor Crane and the Engine Lifting Bracket, remove the engine from the work stand.

Fig 112: Removing Engine From Work Stand Using Floor Crane And Engine Lifting Bracket
Courtesy of FORD MOTOR CO.
Apply a 4 mm (0.15 in) bead of Motorcraft® High Performance Engine RTV Silicone to the rear crankshaft seal retainer mating surface on the engine block.

Fig 113: Locating Bead Of Motorcraft® High Performance Engine RTV Silicone Applying Area
Courtesy of FORD MOTOR CO.
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.

Install the crankshaft rear seal retainer plate and the 6 bolts. Tighten in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 114: Identifying Tightening Sequence Of Retainer Plate Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear seal.

Fig 115: Installing Crankshaft Rear Oil Seal Using Special Tools
Courtesy of FORD MOTOR CO.
Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear seal.

Fig 116: Installing Crankshaft Rear Oil Slinger Using Special Tools
Courtesy of FORD MOTOR CO.
Install the oil pump screen and pickup tube spacer.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 117: Locating Pickup Tube Spacer
  Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Clean and inspect the mating surfaces of the engine block and oil pan.
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 oil pan is not installed and the fasteners tightened within 5 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. If this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque all of the fasteners within 1 hour of applying the sealer.

Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.

Fig 118: Identifying Bead Of Motorcraft® High Performance Engine RTV Silicone Applying Area
Courtesy of FORD MOTOR CO.
Position the oil pan baffle and gasket.

Fig 119: Locating Oil Pan Baffle And Gasket
Courtesy of FORD MOTOR CO.
NOTE: The 2 oil pump screen and pickup tube-to-oil pump bolts must be tightened prior to tightening the oil pump screen and pickup tube-to-spacer bolt.

Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 120: Locating Oil Pump Screen, Pickup Tube And Bolts
  Courtesy of FORD MOTOR CO.
Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

NOTE: Fastener locations 11, 12 and 13 are stud bolts.

Install the oil pan, 13 bolts and 3 stud bolts. Tighten in the sequence shown in illustration.
- Tighten to 25 Nm (18 lb-ft).
Install the engine/transmission spacer plate.

Fig 121: Locating Engine-To-Transmission Spacer Plate
Courtesy of FORD MOTOR CO.
Position the flywheel on the crankshaft pilot and start the 8 flywheel bolts.
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 122: Identifying Flywheel Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.