Section 3 (Engine Mechanical - 2.0L ECOBOOST): Assembly: Engine

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

SPECIAL TOOL(S) / GENERAL EQUIPMENT

	100-002 Holding Fixture with Dial Indicator Gauge
	205-153 Handle
	300-OTC1819E 2, 200# Floor Crane, Fold Away
	303-096 Installer, Camshaft Front Oil Seal TKIT-2009TC-F
	303-1247/2 Installer, VCT Spark Plug Tube Seal
	303-1521 Alignment Tool, Crankshaft Position Sensor
	303-1565 Alignment Tool, Camshaft
	303-1567 Sizer, Teflon Seal
	303-328 Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM TKIT-2009TC-F
	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM
	310-205 Fuel Injector Brush
	310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM
Strap Wrench
Round-Ended Steel Rule

MATERIALS SPECIFICATIONS

Name	Specification
Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP	WSS-M2C946-A
Motorcraft® Metal Surface Prep ZC-31-A	-
flange sealant	WSS-M2G348-A11
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Motorcraft® Orange Antifreeze/Coolant Concentrated VC-3-B	WSS-M97B44-D

NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and 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.

Torque : 10 Nm

Fig 1: Locating Bolts And Engine Piston Oil Coolers
Courtesy of FORD MOTOR CO.
- Measure the length or distance in two directions.
- Record the smallest measurement for each crankshaft main bearing journal.
Fig 2: Identifying Crankshaft Main Bearing Journal Diameters Measuring Directions
Courtesy of FORD MOTOR CO.
Mounted flush and original main bearing beam bolts finger tight.

Fig 3: Locating Main Bearing Beam Bolts
Courtesy of FORD MOTOR CO.
Torque :
Stage 1: 5 Nm

Stage 2: 25 Nm

Stage 3: Tighten an additional 90°

Fig 4: Identifying Original Main Bearing Beam Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Measure each crankshaft block main bearing bore diameter.

Fig 5: Measuring Crankshaft Block Main Bearing Bore Diameter
Courtesy of FORD MOTOR CO.
Using the chart, select the crankshaft main bearings.

Fig 6: Crankshaft Main Bearings Selection Chart
Courtesy of FORD MOTOR CO.
Original connecting rod cap bolts
Torque :

Stage 1: 10 Nm

Stage 2: 29 Nm

Stage 3: Tighten an additional 90°

Fig 7: Locating Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
- Measure the length or distance in two directions.
- Record the smallest measurement for each connecting rod.
Fig 8: Identifying Connecting Rod Large End Bore Measuring Directions
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 9: Locating Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
- Measure the length or distance in two directions.
- Record the smallest measurement for each connecting rod journal.
Fig 10: Identifying Crankshaft Connecting Rod Bearing Journal Diameters Measuring Directions
Courtesy of FORD MOTOR CO.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

Fig 11: Connecting Rod Bearings Selection Chart
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 12: Identifying Main Bearing Beam Bolts Removing Sequence
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.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

Fig 13: Lubricating Upper Crankshaft Main Bearings With Clean Engine Oil

Courtesy of FORD MOTOR CO.

Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

Fig 14: Lubricating Crankshaft Main Bearings With Clean Engine Oil

Courtesy of FORD MOTOR CO.

Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Fig 15: Lubricating Journals On Crankshaft With Clean Engine Oil
Courtesy of FORD MOTOR CO.
Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Fig 16: Lubricating Main Bearing Beam Side Fit Surfaces And Main Bearing Beam Bearings With Clean Engine Oil
Courtesy of FORD MOTOR CO.
Mounted flush.

Fig 17: Positioning Main Bearing Beam In Engine Block With Main Bearing Beam Mounted Flush With Rear Face Of Engine Block
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new main bearing beam bolts threads and under the bolt heads with clean engine oil.

NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

Fig 18: Identifying Main Bearing Beam Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
Torque :

Stage 1: 5 Nm

Stage 2: 25 Nm

Stage 3: Tighten an additional 90°
1. Position the crankshaft to the rear of the cylinder block.
2. Zero the Dial Indicator Gauge with Holding Fixture.
  Special Tool(s) : 100-002 (Holding Fixture with Dial Indicator Gauge)
3. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
4. Acceptable crankshaft end play is 0.220-0.450 mm (0.0087-0.0177 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
Fig 19: Measuring Crankshaft End Play Using Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.

NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

Fig 20: Lubricating Connecting Rod Bearings

Courtesy of FORD MOTOR CO.

Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
1. Upper oil control segment ring gap location.
2. Oil control spacer gap location.
3. Lower oil control segment ring gap location.
Fig 21: Identifying Piston Ring Gap Locations
Courtesy of FORD MOTOR CO.

NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

Fig 22: Lubricating Piston, Connecting Rod And Piston Ring Compressor

Courtesy of FORD MOTOR CO.

Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

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

Fig 23: Locating Connecting Rod Caps Bolts

Courtesy of FORD MOTOR CO.

Torque :
Stage 1: 10 Nm

Stage 2: 29 Nm

Stage 3: Tighten an additional 90°
- Install the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
- Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
Fig 24: Locating Timing Peg - 303-507
Courtesy of FORD MOTOR CO.

NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

NOTE: The original adjustment shims must be installed in their original positions.

NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.

Fig 25: Locating Balancer Unit Shaft Marks At TDC Position

Courtesy of FORD MOTOR CO.

Install the adjustment shims in their original positions on the seat faces of the balancer unit. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
Torque :
Stage 1: 25 Nm

Stage 2: 42 Nm

Fig 26: Identifying Balancer Unit Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
- Remove the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
- Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
Fig 27: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
1. Install the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
2. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
3. Remove the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
Fig 28: Locating Timing Peg - 303-507
Courtesy of FORD MOTOR CO.
NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.

NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown in illustration. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.

NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration.

NOTE: Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash.
1. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
2. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
3. Backlash specifications are 0.020 to 0.120 mm (0.00078 to 0.0047 in).
4. If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure.
  Refer to: Balance Shaft Backlash .
Fig 29: Locating Bolts And Connecting Rod Caps
Courtesy of FORD MOTOR CO.
Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.

Fig 30: Locating Timing Peg - 303-507
Courtesy of FORD MOTOR CO.
Torque :
Stage 1: 10 Nm

Stage 2: 20 Nm

Fig 31: Identifying Oil Pump Assembly Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Torque : 25 Nm

Fig 32: Locating Oil Pump Sprocket Bolt
Courtesy of FORD MOTOR CO.
Fig 33: Locating Diamond Washer
Courtesy of FORD MOTOR CO.
Fig 34: Identifying Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
1. Torque : 10 Nm
2. Push the tensioner spring down and position the spring under the shoulder bolt.
Fig 35: Locating Tensioner Spring And Shoulder Bolts
Courtesy of FORD MOTOR CO.
Special Tool(s) : 303-328 (Replacer, Rear Seal)
Torque : 10 Nm

Fig 36: Identifying Crankshaft Rear Oil Seal Retainer Plate Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: A new gasket must be installed.

Fig 37: Locating Gasket On Oil Pump Screen And Pickup Tube
Courtesy of FORD MOTOR CO.
Torque : 10 Nm

Fig 38: Locating Oil Pump Screen And Pickup Tube Bolts
Courtesy of FORD MOTOR CO.

NOTE: If the oil pan is not secured within 10 minutes of sealant application, 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 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Fig 39: Applying Bead Of Silicone Gasket And Sealant To Oil Pan-To-Engine Block Mating Surface

Courtesy of FORD MOTOR CO.

Apply a continuous bead of the specified diameter from the specified tube.
Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- Finger-tight.
Fig 40: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Front surface of the oil pan flush with the front surface of the engine block.
General Equipment : Round-Ended Steel Rule

Fig 41: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block
Courtesy of FORD MOTOR CO.
Torque : 20 Nm

Fig 42: Identifying Oil Pan Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Fig 43: Locating Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
Fig 44: Identifying Cylinder Head Gasket
Courtesy of FORD MOTOR CO.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

Fig 45: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Torque :
Stage 1: 7 Nm

Stage 2: 15 Nm

Stage 3: 55 Nm

Stage 4: Tighten 90°

Stage 5: Tighten an additional 90°
Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Fig 46: Lubricating Valve Tappets With Clean Engine Oil
Courtesy of FORD MOTOR CO.

NOTE: The exhaust camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.

NOTE: Do not allow Gasket Maker to enter the camshaft bearing journal. If Gasket Maker is applied to the camshaft bearing journal, the journal and sealing area must be cleaned with Motorcraft® Metal Surface Prep.

Fig 47: Applying Beads Of Gasket Maker To Exhaust Rear Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

Apply a continuous bead of the specified diameter from the specified tube.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Material : Motorcraft® Metal Surface Prep / ZC-31-A
NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.

NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.

NOTE: Wipe off any excess sealer from the fuel injection pump housing sealing surface of the cylinder head and rear camshaft cap.

NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil.
- Apply the specified lubricant to the specified component.
  Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
- Tighten 2 turns at a time in the sequence shown in illustration in 2 stages.
  Torque :
  
  Stage 1: 7 Nm
  
  Stage 2: 16 Nm
Fig 48: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Torque :

Stage 1: 7 Nm

Stage 2: 16 Nm

Fig 49: Lubricating Camshaft Journals And Front Camshaft Bearing Cap With Clean Engine Oil
Courtesy of FORD MOTOR CO.
Torque : 10 Nm

Fig 50: Locating Bolts And Variable Camshaft Timing Solenoids
Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Fig 51: Installing Camshaft Alignment Tool Into Rear Of Both Of Camshaft Slots

Courtesy of FORD MOTOR CO.

Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
NOTE: Do not reuse the camshaft phaser and sprocket washers. New washers must be installed.

Fig 52: Locating Camshaft Phaser And Sprocket Washers
Courtesy of FORD MOTOR CO.
NOTE: Do not tighten the camshaft phaser and sprocket bolts at this time.
- Finger-tight.
Fig 53: Locating Bolts Of Intake And Exhaust Camshaft Phaser And Sprockets
Courtesy of FORD MOTOR CO.
Torque : 10 Nm

Fig 54: Locating Timing Chain Tensioner Arm And Bolts
Courtesy of FORD MOTOR CO.

NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Fig 55: Compressing Timing Chain Tensioner Plunger Using Edge Of Vise

Courtesy of FORD MOTOR CO.

Using the edge of a vise, compress the timing chain tensioner plunger.
Using a small pick, push back and hold the ratchet mechanism.

Fig 56: Pushing Back And Hold Ratchet Mechanism Using Small Pick
Courtesy of FORD MOTOR CO.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 57: Pushing Ratchet Arm Back Into Tensioner Housing While Holding Ratchet Mechanism
Courtesy of FORD MOTOR CO.
Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

Fig 58: Installing Holding Pin Into Hole In Tensioner Housing
Courtesy of FORD MOTOR CO.

NOTE: Do not remove the holding pin until the tensioner bolts are tightened.

Fig 59: Locating Holding Pin And Tensioner Bolts

Courtesy of FORD MOTOR CO.

Torque : 10 Nm

NOTE: Use an open-ended wrench to prevent the component from turning.

Fig 60: Loosening Exhaust Camshaft Phaser And Sprocket Bolt Using Wrench On Flats Of Exhaust Camshaft To Prevent Camshaft Rotation

Courtesy of FORD MOTOR CO.

Torque : 72 Nm

NOTE: Use an open-ended wrench to prevent the component from turning.

Fig 61: Loosening Intake Camshaft Phaser And Sprocket Bolt Using Wrench On Flats Of Intake Camshaft To Prevent Camshaft Rotation

Courtesy of FORD MOTOR CO.

Torque : 72 Nm

NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.

Fig 62: Applying Bead Of Silicone Gasket And Sealant To Sealing Surface Of Front Cover

Courtesy of FORD MOTOR CO.

Apply a continuous bead of the specified diameter from the specified tube.
Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

Material : Motorcraft® Metal Surface Prep / ZC-31-A

NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.

Fig 63: Applying Beads Of Silicone Gasket And Sealant In Length Across Cylinder Head And Cylinder Block Joint Areas

Courtesy of FORD MOTOR CO.

Apply beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas.
Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

Material : Motorcraft® Metal Surface Prep / ZC-31-A
Torque :
Bolts 1 - 19 10 Nm

Bolts 20 - 22 48 Nm

Fig 64: Identifying Engine Front Cover Bolts And Stud Bolts Tighten Sequence
Courtesy of FORD MOTOR CO.

NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

Fig 65: Installing Crankshaft Front Oil Seal Using Camshaft Front Oil Seal Installer

Courtesy of FORD MOTOR CO.

Apply the specified lubricant to the specified component.
Special Tool(s) : 303-096 (Installer, Camshaft Front Oil Seal)

Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
NOTE: Do not reuse the diamond washer, a new diamond washer must be installed.

Fig 66: Locating Diamond Washer In Crankshaft
Courtesy of FORD MOTOR CO.
Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Fig 67: Applying Clean Engine Oil On Seal Contact Area Of Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Fig 68: Locating Crankshaft Pulley Alignment Hole
Courtesy of FORD MOTOR CO.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Fig 69: Locating Crankshaft Pulley Alignment Bolt

Courtesy of FORD MOTOR CO.

Install an M6 bolt.
NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be installed using hand tools only.
- Strap Wrench.
- Do not use power tools.
  General Equipment : Strap Wrench
  
  Torque :
  
  Stage 1: 100 Nm
  
  Stage 2: Tighten an additional 90°
Fig 70: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the M6 bolt.

Fig 71: Locating Crankshaft Pulley Alignment Bolt
Courtesy of FORD MOTOR CO.
NOTE: Do not tighten the CKP sensor bolts at this time.

Fig 72: Locating CKP Sensor Bolts
Courtesy of FORD MOTOR CO.
Install the Special Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel.
Special Tool(s) : 303-1521 (Alignment Tool, Crankshaft Position Sensor)

Torque : 7 Nm

Fig 73: Locating Crankshaft Sensor Alignment Tool And Crankshaft Sensor Bolts
Courtesy of FORD MOTOR CO.
Remove the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)

Fig 74: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)

Fig 75: Installing Camshaft Alignment Tool Into Rear Of Both Of Camshaft Slots
Courtesy of FORD MOTOR CO.
Torque : 20 Nm

Fig 76: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
Torque : 63 Nm

Fig 77: Identifying Brake Vacuum Pump Adapter
Courtesy of FORD MOTOR CO.

NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.

Fig 78: Applying Sealant On Intake Camshaft Rear Bearing Cap

Courtesy of FORD MOTOR CO.

Apply a continuous bead of the specified diameter from the specified tube.
Material : flange sealant (WSS-M2G348-A11)

Material : Motorcraft® Metal Surface Prep / ZC-31-A

NOTE: Wipe off any excess sealer from the vacuum pump sealing surface of the cylinder head and camshaft cap.

Fig 79: Locating Rear Intake Camshaft Cap And Bolts

Courtesy of FORD MOTOR CO.

Torque :
Stage 1: 7 Nm

Stage 2: 16 Nm

NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

Fig 80: Installing VCT Solenoid Seals Using VCT Spark Plug Tube Seal Installer And Handle

Courtesy of FORD MOTOR CO.

Special Tool(s) : 205-153 (Handle) , 303-1247/2 (Installer, VCT Spark Plug Tube Seal)
Fig 81: Applying Sealant On Valve Cover
Courtesy of FORD MOTOR CO.
Apply a bead of the specified diameter from the specified tube.
Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

Fig 82: Identifying Silicone Gasket And Sealant Applying Areas
Courtesy of FORD MOTOR CO.

NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.

Fig 83: Identifying Valve Cover Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Material : Motorcraft® Metal Surface Prep / ZC-31-A
Torque : 10 Nm
1. Early build vehicles equipped with metal vacuum tubes.
2. Late build vehicles equipped with nylon vacuum tubes.
Fig 84: Locating Vacuum Hose Retainers
Courtesy of FORD MOTOR CO.
Torque : 6 Nm

Fig 85: Locating Bolts And Coil-On-Plugs
Courtesy of FORD MOTOR CO.
Fig 86: Locating Wiring Harness Electrical Connectors And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.

NOTE: The fuel injection cam lobe must be positioned at zero lift before installing the fuel injection pump housing.

Fig 87: Rotating Engine Clockwise Until Fuel Injection Cam Lobe Is At Zero Lift Using Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

Turn the component clockwise.
- Visual check.
- Replace as necessary.
Fig 88: Inspecting Fuel Injection Pump Housing Gasket
Courtesy of FORD MOTOR CO.
Torque :
Stage 1: 15 Nm

Stage 2: Tighten an additional 60°

Fig 89: Locating Stud Bolts And Fuel Injection Pump Housing
Courtesy of FORD MOTOR CO.
Visual check. Inspect the fuel injection pump tappet for flat spots or scoring, especially in the indicated areas. If any damage is found, inspect the fuel injection pump and the fuel injection pump tappet drive lobe. Install new components as necessary.

Fig 90: Locating Coil-On-Plugs Bolts
Courtesy of FORD MOTOR CO.
Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Fig 91: Locating Wiring Harness Retainers And Wiring Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Fig 92: Lubricating Fuel Injection O-Ring Seal
Courtesy of FORD MOTOR CO.
Alternately tighten each bolt one complete revolution until seated.
Torque :

Stage 1: 5 Nm

Stage 2: Tighten an additional 55°

Fig 93: Locating Fuel Injection Pump Bolts
Courtesy of FORD MOTOR CO.
- Torque : 17 Nm
Fig 94: Locating Bolts And Fuel Injection Pump Bracket
Courtesy of FORD MOTOR CO.
- Visual check.
- Replace as necessary.
Fig 95: Inspecting Brake Vacuum Pump Gasket
Courtesy of FORD MOTOR CO.
Torque : 10 Nm

Fig 96: Locating Brake Vacuum Pump Bolts
Courtesy of FORD MOTOR CO.
Fig 97: Identifying Brake Vacuum Pump
Courtesy of FORD MOTOR CO.
- Visual check.
- Replace as necessary.
Fig 98: Inspecting Thermostat Housing Gasket
Courtesy of FORD MOTOR CO.
Torque : 10 Nm

Fig 99: Locating Thermostat Housing Bolts
Courtesy of FORD MOTOR CO.

NOTE: Do not use compressed air or the Fuel Injector Brush to clean the tip of the fuel injectors. Failure to follow this instruction may result in damage to the fuel injectors.

NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

Fig 100: Cleaning Fuel Injector Orifices Using Fuel Injector Brush

Courtesy of FORD MOTOR CO.

Special Tool(s) : 310-205 (Fuel Injector Brush)
NOTE: Place the Teflon® Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
1. Special Tool(s) : 303-1567 (Sizer, Teflon Seal)
2. Special Tool(s) : 310-207 (Installer, Fuel Injector Seal Assembly)
3. NOTE: Make sure that new lower fuel injector Teflon® seals are installed.
4. Special Tool(s) : 310-207 (Installer, Fuel Injector Seal Assembly)
Fig 101: Installing Lower Teflon Fuel Injector Seals
Courtesy of FORD MOTOR CO.

NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the seal.

NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.

Fig 102: Sliding Teflon Seal Sizer Down Over Teflon Seal

Courtesy of FORD MOTOR CO.

Special Tool(s) : 303-1567 (Sizer, Teflon Seal)

NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

Fig 103: Locating Upper Fuel Injector O-Ring Seal Support Ring, Upper Fuel Injector O-Ring Seal And Fuel Injector Retainer Clip

Courtesy of FORD MOTOR CO.

Apply the specified lubricant to the specified component.
Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.

NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

Fig 104: Identifying Fuel Injectors In Fuel Rail
Courtesy of FORD MOTOR CO.

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

NOTE: Make sure that new fuel rail bolts are installed.

Fig 105: Identifying Fuel Rail Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Push down on the fuel rail above the injectors.
Torque :

Stage 1: 8 Nm

Stage 2: 26°
- Finger-tight.
Fig 106: Locating High Pressure Fuel Tube And Flare Nuts
Courtesy of FORD MOTOR CO.
- Finger-tight.
Fig 107: Locating High Pressure Fuel Tube Bracket Bolts
Courtesy of FORD MOTOR CO.
Torque :
Stage 1: 15 Nm

Stage 2: Tighten an additional 30°

Fig 108: Locating High Pressure Fuel Tube Flare Nuts
Courtesy of FORD MOTOR CO.
Torque : 10 Nm

Fig 109: Locating High Pressure Fuel Tube Bracket Bolts
Courtesy of FORD MOTOR CO.
Fig 110: Locating Pin-Type Retainers And Fuel Rail Insulator
Courtesy of FORD MOTOR CO.
Fig 111: Locating Fuel Injector Electrical Connectors And Fuel Charge Wiring Harness
Courtesy of FORD MOTOR CO.
- Visual check.
- Replace as necessary.
Fig 112: Inspecting Crankcase Vent Oil Separator Gasket
Courtesy of FORD MOTOR CO.
Torque : 10 Nm

Fig 113: Locating Crankcase Vent Oil Separator Bolts And Coolant Bypass Hose Clamps
Courtesy of FORD MOTOR CO.

NOTE: The forward KS must be installed in the 6 o'clock position and the rearward KS must be installed in the 3 o'clock position as shown in illustration . Failure to follow these instructions may result in damage to the engine.

Fig 114: Locating KS Electrical Connectors, KS Bolts And Wiring Harness Retainers

Courtesy of FORD MOTOR CO.

Torque : 20 Nm
Fig 115: Identifying Connector Bolts
Courtesy of FORD MOTOR CO.
Torque : 20 Nm

Fig 116: Identifying Intake Manifold Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Fig 117: Locating MAP Sensor, FRP Sensor And Fuel Charge Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
Torque : 11 Nm

Fig 118: Identifying Fastener And Bolts
Courtesy of FORD MOTOR CO.
Fig 119: Locating Tube Retainers
Courtesy of FORD MOTOR CO.
1. Refer to: QUICK RELEASE COUPLING .
Fig 120: Locating Hose Retainers
Courtesy of FORD MOTOR CO.
Torque : 25 Nm

Fig 121: Locating Oil Filter Adapter Bolts And EOP Switch Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
- Torque :
  Stage 1: 23 Nm
  
  Stage 2: Tighten an additional 75°
- Pause.
  Torque : Tighten an additional 15°
Fig 122: Locating Oil Cooler Bolt
Courtesy of FORD MOTOR CO.
Fig 123: Locating Coolant Hoses Clamps
Courtesy of FORD MOTOR CO.
NOTE: Install a new coolant pump O-ring seal and lubricate with clean engine coolant prior to installation.
1. Material : Motorcraft® Orange Antifreeze/Coolant Concentrated / VC-3-B (WSS-M97B44-D)
  Torque : 10 Nm
2. Torque : 25 Nm
Fig 124: Locating Coolant Hoses Clamps
Courtesy of FORD MOTOR CO.
1. Finger-tight.
2. Torque : 25 Nm
Fig 125: Locating Coolant Pump Bolts And Idler Pulley Bracket Bolt And Nut
Courtesy of FORD MOTOR CO.
Torque : 15 Nm

Fig 126: Locating Generator Nut, Wire Terminal And Wire Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Fig 127: Locating Generator Cap
Courtesy of FORD MOTOR CO.
Torque : 25 Nm

Fig 128: Locating A/C Compressor, Bolts, Connector And Tube Retainer
Courtesy of FORD MOTOR CO.
Torque : 5 Nm

Fig 129: Identifying Hose Clamp
Courtesy of FORD MOTOR CO.
Fig 130: Locating Generator Wire Terminal Cap
Courtesy of FORD MOTOR CO.
Refer to: AIR CONDITIONING (A/C) COMPRESSOR BELT .
Torque : 20 Nm

Fig 131: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
Torque : 25 Nm

Fig 132: Locating Bolts And Halfshaft Bracket
Courtesy of FORD MOTOR CO.
1. Torque : 25 Nm
2. Torque : 20 Nm
3. Torque : 10 Nm
Fig 133: Locating CHT Sensor Electrical Connector, Wiring Harness Retainer, ECT Sensor Electrical Connector And Ground Wire And Bolt
Courtesy of FORD MOTOR CO.
Torque : 17 Nm

Fig 134: Locating Turbocharger-To-Cylinder Head Studs
Courtesy of FORD MOTOR CO.
Fig 135: Identifying Turbocharger Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.
Torque : 10 Nm

Fig 136: Locating Bolts And Turbocharger Heat Shield
Courtesy of FORD MOTOR CO.

NOTE: Do not reuse the turbocharger oil return tube/gaskets, new parts must be installed.

Fig 137: Locating Turbocharger Heat Shield Bolts

Courtesy of FORD MOTOR CO.

Torque : 10 Nm
NOTE: Do not reuse the turbocharger oil filter, a new part must be installed.

Fig 138: Locating Gaskets And Turbocharger Oil Return Tube Bolts
Courtesy of FORD MOTOR CO.

NOTE: Do not reuse the turbocharger oil supply tube gaskets, new parts must be installed.

Fig 139: Identifying Turbocharger Oil Filter

Courtesy of FORD MOTOR CO.

Torque : 25 Nm
Fig 140: Locating Electrical Connector And Turbocharger Control Vacuum Hoses Clamps
Courtesy of FORD MOTOR CO.

NOTE: Do not reuse the gaskets, new parts must be installed.

Fig 141: Locating Gaskets, Turbocharger Oil Supply Tube And Banjo Bolts

Courtesy of FORD MOTOR CO.

Torque : 28 Nm
Fig 142: Locating Wiring Harness Retainers On Engine Front Cover
Courtesy of FORD MOTOR CO.
Fig 143: Locating CKP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Torque : 5 Nm

Fig 144: Locating Intake Manifold Hose Bracket Bolt And Stud
Courtesy of FORD MOTOR CO.
Torque : 5 Nm

Fig 145: Locating Turbocharger Inlet Tube Clamp
Courtesy of FORD MOTOR CO.
Install the Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away)

Fig 146: Installing Floor Crane And Spreader Bar On Engine
Courtesy of FORD MOTOR CO.
Remove.

Fig 147: Installing Engine On Engine Stand
Courtesy of FORD MOTOR CO.

NOTE: Special bolts are used for installation. Do not use standard bolts.

Fig 148: Identifying Flexplate Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Torque :
Stage 1: 50 Nm

Stage 2: 80 Nm

Stage 3: 112 Nm
Special Tool(s): Universal clutch alignment tool.

Fig 149: Installing Clutch On Universal Clutch Alignment Tool
Courtesy of FORD MOTOR CO.
Tighten each bolt 2 turns at a time.
Torque : 29 Nm

Fig 150: Identifying Clutch Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.