Lower Engine Block (View 2)

Fig 1: Exploded View Of Lower Engine Block (View 2)

Courtesy of FORD MOTOR CO.

All vehicles 

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

   Select the crankshaft main bearings for each crankshaft journal.

   • Read the code on the crankshaft flange.
   • Read the code on the cylinder block face.
     • The first letter after the first asterisk makes up the code for main No. 1 and the next letter for main No. 2. The first letter after the second asterisk makes up the code for main No. 3 and the last letter for main No. 4.
       Fig 2: Locating Code On Crankshaft Flange And Code On Cylinder Block Face

       Courtesy of FORD MOTOR CO.
2. Using a hexagonal screwdriver, install the 6 piston oil cool valves.
   • Tighten to 4 Nm (35 lb-in).
     Fig 3: Locating Piston Oil Cool Valves

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

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

   • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing.
   • Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
     Fig 4: Bearing Select Fit Chart - Main Bearings 1 And 4

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

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

   • Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is "1".
   • Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
     Fig 5: Bearing Select Fit Chart - Main Bearings 2 And 3

     Courtesy of FORD MOTOR CO.
5. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

   Using the original connecting rod cap bolts, install the connecting rod caps and bolts.

   • Tighten the bolts in 3 stages.
   • Stage 1: Tighten to 23 Nm (17 lb-ft).
   • Stage 2: Tighten to 43 Nm (32 lb-ft).
   • Stage 3: Tighten an additional 90 degrees.
6. Measure the connecting rod large end bore in 2 directions. For additional information, refer to GENERAL SPECIFICATIONS  under Specifications.
   • Remove the bolts and the rod cap.
     • Discard the connecting rod cap bolts.
       Fig 6: Identifying Connecting Rod Large End Bore Measure Directions

       Courtesy of FORD MOTOR CO.
7. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. For additional information, refer to GENERAL SPECIFICATIONS  under Specifications.
   Fig 7: Identifying Crankshaft Connecting Rod Bearing Journal Diameters Measure Directions

   Courtesy of FORD MOTOR CO.
8. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
   Fig 8: Connecting Rod Bearing Selecting Chart

   Courtesy of FORD MOTOR CO.
9. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

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

   Fig 9: Locating Crankshaft Main Bearings In Cylinder Block

   Courtesy of FORD MOTOR CO.
10. NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
    NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.

    Install the crankshaft onto the upper main bearings.

    Fig 10: Locating Crankshaft Onto Upper Main Bearings

    Courtesy of FORD MOTOR CO.
11. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

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

    Fig 11: Installing Rear Crankshaft Upper Thrust Washer At Back Of No. 4 Rear Bulkhead

    Courtesy of FORD MOTOR CO.
12. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

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

    Fig 12: Installing Front Crankshaft Upper Thrust Washer At Front Of No. 4 Rear Bulkhead

    Courtesy of FORD MOTOR CO.
13. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.
    Fig 13: Locating Crankshaft Main Bearing In Main Bearing Cap

    Courtesy of FORD MOTOR CO.
14. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
    Fig 14: Locating No. 1, No. 2 And No. 3 Main Bearing Caps On Cylinder Block

    Courtesy of FORD MOTOR CO.
15. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
    NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

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

    Fig 15: Aligning Lower Crankshaft Thrust Washer Tab With Cutout In No. 4 Rear Main Bearing Cap

    Courtesy of FORD MOTOR CO.
16. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
    Fig 16: Locating Main Bearing Cap No. 4 On Cylinder Block

    Courtesy of FORD MOTOR CO.
17. Loosen the No. 4 main bearing cap bolts.
18. NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.

    Tighten the main bearing bolts in 2 stages in the sequence shown in illustration.

    • Stage 1: Tighten fasteners 1 through 8 to 33 Nm (24 lb-ft).
    • Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
      Fig 17: Identifying Bearing Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
19. Install the new 8 main bearing cap side bolts. Tighten in 2 stages in the sequence shown in illustration.
    • Stage 1: Tighten fasteners 1 through 8 to 45 Nm (33 lb-ft).
    • Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
      Fig 18: Identifying Main Bearing Cap Side Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
20. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
    • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
      Fig 19: Measuring Crankshaft End Play Using Dial Indicator Gauge With Holding Fixture

      Courtesy of FORD MOTOR CO.
21. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Prepare the connecting rod and cap.

    • Insert the new bolts in the rod cap.
    • Insert the upper and lower rod bearings into the rod and cap.
      Fig 20: Locating Connecting Rod Cap And Bolts

      Courtesy of FORD MOTOR CO.
22. Before installing the pistons into the cylinder block, verify proper ring gap location.
    1. Center line of the piston parallel to the wrist pin bore
    2. Upper compression ring gap location
    3. Upper oil control segment ring gap location
    4. Lower oil control segment ring gap location
    5. Expander ring and lower compression ring gap location
       Fig 21: Identifying Piston Rings End Gap Position

       Courtesy of FORD MOTOR CO.
23. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
    NOTE: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown in illustration.
    NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
    NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to PISTON .
    NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.
    NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.

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

    Fig 22: Installing Piston And Connecting Rod Assemblies Using Piston Ring Compressor

    Courtesy of FORD MOTOR CO.
24. Seat the connecting rod on the crankshaft journal.
25. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation.

    Install the connecting rod cap and bolts. Tighten the bolts in 3 stages.

    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
      Fig 23: Identifying Connecting Rod Cap And Bolts

      Courtesy of FORD MOTOR CO.
26. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
27. Install the main bearing cap support brace and the new bolts. Tighten in 2 stages in the sequence shown in illustration.
    • Stage 1: Tighten fasteners to 24 Nm (18 lb-ft).
    • Stage 2: Tighten fasteners an additional 180 degrees.
      Fig 24: Identifying Main Bearing Cap Support Brace Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
28. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.
    NOTE: Cast aluminum (early build) crankshaft rear seal retainer plate shown in illustration, stamped steel (late build) crankshaft rear seal retainer plate is similar.
    NOTE: The stamped steel (late build) crankshaft rear seal retainer plate comes with the crankshaft rear seal.

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

    Fig 25: Applying RTV Silicone To Sealing Surface Of Crankshaft Rear Seal Retainer

    Courtesy of FORD MOTOR CO.

    Cast aluminum (early build) crankshaft retainer plate 

29. Install the crankshaft rear seal retainer plate and the 8 bolts. Tighten in the sequence shown in illustration.
    • Tighten to 10 Nm (89 lb-in).
      Fig 26: Identifying Crankshaft Rear Seal Retainer Plate Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.

      Stamped steel (late build) crankshaft rear seal retainer plate 

30. NOTE: Lubricate the crankshaft rear seal and the crankshaft with clean engine oil prior to installation.
    NOTE: Use the handles during installation to avoid touching the sealant.

    Install the 8 crankshaft rear seal retainer plate bolts. Tighten in the sequence shown in illustration.

    • Tighten to 10 Nm (89 lb-in).
      Fig 27: Identifying Crankshaft Rear Seal Retainer Plate Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.

    All vehicles 

31. Install the oil pump and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Locating Bolts And Oil Pump

      Courtesy of FORD MOTOR CO.
32. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 29: Locating Bolts, Oil Pump Screen And Pickup Tube

      Courtesy of FORD MOTOR CO.
33. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

    Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone on the inside edge of the oil pan to the sealing surface of the oil pan-to-engine block mating surface.

    Fig 30: Applying RTV Silicone On Inside Edge Of Oil Pan Sealing Surface-To-Engine Block Mating Surface

    Courtesy of FORD MOTOR CO.
34. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
    Fig 31: Applying RTV Silicone To The 2 Crankshaft Seal Retainer Plate-To-Cylinder Block Joint Areas On The Sealing Surface Of Oil Pan

    Courtesy of FORD MOTOR CO.
35. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

    Install the oil pan and bolts 10, 11, 13 and 14 finger tight.

    Fig 32: Identifying Oil Pan Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
36. Laterally align the oil pan to the block. Make sure the oil pan is flush with the block at these 2 points.
    Fig 33: Locating Oil Pan Flush Point With Block

    Courtesy of FORD MOTOR CO.
37. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration.
    • Tighten to 3 Nm (27 lb-in).
      Fig 34: Identifying Oil Pan Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
38. Install the remaining oil pan bolts and tighten in the sequence shown in illustration.
    • Tighten bolts 1-9 and 11-14 to 20 Nm (177 lb-in), then rotate an additional 45 degrees.
    • Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees.
    • Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.
      Fig 35: Identifying Oil Pan Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
39. Install the Knock Sensor (KS) and the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 36: Locating Knock Sensors And Bolts

      Courtesy of FORD MOTOR CO.
40. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in 5 stages in the sequence shown in illustration.
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 45 degrees.
      Fig 37: Identifying RH Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
41. Install the new M6 bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 38: Locating Cylinder Head M6 Bolt

      Courtesy of FORD MOTOR CO.
42. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in 5 stages in the sequence shown in illustration.
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 45 degrees.
      Fig 39: Identifying Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
43. Install the new M6 bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 40: Locating Cylinder Head M6 Bolt

      Courtesy of FORD MOTOR CO.
44. NOTE: The valve tappets must be installed in their original positions.
    NOTE: Coat the valve tappets with clean engine oil prior to installation.
    NOTE: LH shown in illustration, RH similar.

    Install the valve tappets.

    Fig 41: Locating Valve Tappet

    Courtesy of FORD MOTOR CO.
45. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

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

    Fig 42: Locating Crankshaft Dowel Pin At 9 O'Clock Position

    Courtesy of FORD MOTOR CO.
46. NOTE: Coat the camshafts with clean engine oil prior to installation.

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

    Fig 43: Positioning Camshafts Onto RH Cylinder Head In Neutral Position

    Courtesy of FORD MOTOR CO.
47. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the 4 camshaft seals gaps as shown in illustration.

    Fig 44: Locating Camshaft Seals Gaps

    Courtesy of FORD MOTOR CO.
48. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration.

    • Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
      Fig 45: Identifying Cylinder Head Camshaft Bearing Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
49. Loosen the 4 camshaft caps bolts.
    Fig 46: Locating Camshaft Caps Bolts

    Courtesy of FORD MOTOR CO.
50. Tighten the 4 camshaft caps bolts in the sequence shown in illustration.
    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
      Fig 47: Identifying Camshaft Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
51. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to VALVE CLEARANCE CHECK .

    Fig 48: Measuring Valve Tappet Clearance Using Feeler Gauge

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

    Apply a 3 mm (0.118 in) bead of sealant to the camshaft bearing cap assembly.

    Fig 49: Applying Bead Of Sealant On Camshaft Bearing Cap Assembly

    Courtesy of FORD MOTOR CO.
53. Install the camshaft bearing cap assembly and the 2 bolts.
    • Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Remove the excess gasket maker.
      Fig 50: Locating Bolts And Camshaft Bearing Cap Assembly

      Courtesy of FORD MOTOR CO.
54. Remove the 3 bolts and the RH valve train oil tube.
    Fig 51: Locating Bolts And RH Valve Train Oil Tube

    Courtesy of FORD MOTOR CO.
55. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown in illustration.
    Fig 52: Locating RH Camshafts At TDC Position

    Courtesy of FORD MOTOR CO.
56. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

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

    Fig 53: Identifying Camshaft Holding Tool

    Courtesy of FORD MOTOR CO.
57. NOTE: Coat the camshafts with clean engine oil prior to installation.

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

    Fig 54: Positioning Camshafts Onto LH Cylinder Head In Neutral Position

    Courtesy of FORD MOTOR CO.
58. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the 4 camshaft seals gaps as shown in illustration.

    Fig 55: Locating Camshaft Seals Gaps

    Courtesy of FORD MOTOR CO.
59. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration.

    • Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
      Fig 56: Identifying Cylinder Head Camshaft Bearing Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
60. Loosen the 4 camshaft caps bolts.
    Fig 57: Locating Camshaft Caps Bolts

    Courtesy of FORD MOTOR CO.
61. Tighten the 4 camshaft caps bolts in the sequence shown in illustration.
    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
      Fig 58: Identifying Camshaft Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
62. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to VALVE CLEARANCE CHECK .

    Fig 59: Measuring Valve Tappet Clearance Using Feeler Gauge

    Courtesy of FORD MOTOR CO.
63. Remove the 3 bolts and the LH valve train oil tube.
    Fig 60: Locating Bolts And LH Valve Train Oil Tube

    Courtesy of FORD MOTOR CO.
64. Rotate the LH camshafts to the TDC position as shown in illustration.
    Fig 61: Locating LH Camshafts At TDC Position

    Courtesy of FORD MOTOR CO.
65. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

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

    Fig 62: Identifying Camshaft Holding Tool

    Courtesy of FORD MOTOR CO.
66. Using a new gasket, install the timing chain gear and the 9 bolts. Tighten in 2 stages in the sequence shown in illustration.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
      Fig 63: Identifying Timing Chain Gear And Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
67. Install the RH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 64: Locating RH Primary Timing Chain Guide And Bolts

      Courtesy of FORD MOTOR CO.

    Engines with secondary timing chain tensioner removed 

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

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

    Fig 65: Installing RH Secondary Timing Chain Tensioner By Pushing It Down All Way Until Snap Is Heard

    Courtesy of FORD MOTOR CO.
69. Install the RH secondary timing chain tensioner shoe.
    Fig 66: Locating RH Secondary Timing Chain Tensioner Shoe

    Courtesy of FORD MOTOR CO.
70. Remove and discard the RH secondary timing chain tensioner shipping clip.
    Fig 67: Locating RH Secondary Timing Chain Tensioner Shipping Clip

    Courtesy of FORD MOTOR CO.
71. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
    • Align the colored links with the timing marks.
      Fig 68: Aligning Colored Links With Timing Marks

      Courtesy of FORD MOTOR CO.
72. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

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

    Fig 69: Aligning Holes In VCT Assemblies With Dowel Pins In Camshafts

    Courtesy of FORD MOTOR CO.
73. Install the 2 new RH VCT bolts and tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
      Fig 70: Locating RH VCT Bolts

      Courtesy of FORD MOTOR CO.
74. Activate the RH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
    Fig 71: Activating RH Secondary Timing Chain Tensioner By Pressing Down On Secondary Tensioner Shoe

    Courtesy of FORD MOTOR CO.
75. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
    NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    Install the RH exhaust VCT oil control solenoid.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
      Fig 72: Locating RH Exhaust VCT Oil Control Solenoid And Bolt

      Courtesy of FORD MOTOR CO.
76. NOTE: Apply clean engine oil to the secondary timing chain tensioner O-ring seals and mega cap bore.
    NOTE: Do not remove the secondary timing chain tensioner shipping clip, until instructed to do so.

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

    Fig 73: Installing LH Secondary Timing Chain Tensioner By Pushing It Down All Way Until Snap Is Heard

    Courtesy of FORD MOTOR CO.
77. Install the LH secondary timing chain tensioner shoe.
    Fig 74: Locating LH Secondary Timing Chain Tensioner Shoe

    Courtesy of FORD MOTOR CO.
78. Remove and discard the LH secondary timing chain tensioner shipping clip.
    Fig 75: Locating LH Secondary Timing Chain Tensioner Shipping Clip

    Courtesy of FORD MOTOR CO.
79. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
    • Align the colored links with the timing marks.
      Fig 76: Aligning Colored Links With Timing Marks

      Courtesy of FORD MOTOR CO.
80. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

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

    Fig 77: Aligning Holes In VCT Assemblies With Dowel Pins In Camshafts

    Courtesy of FORD MOTOR CO.
81. Install the 2 new LH VCT bolts and tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
      Fig 78: Locating LH VCT Bolts

      Courtesy of FORD MOTOR CO.
82. Activate the LH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
    Fig 79: Activating LH Secondary Timing Chain Tensioner By Pressing Down On Secondary Tensioner Shoe Until It Bottoms Out

    Courtesy of FORD MOTOR CO.
83. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
    NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    Install the LH exhaust VCT oil control solenoid.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
      Fig 80: Locating LH Exhaust VCT Oil Control Solenoid And Bolt

      Courtesy of FORD MOTOR CO.

    Engines with secondary timing chain tensioner not removed 

84. Compress the RH secondary chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
    Fig 81: Compressing RH Secondary Timing Chain Tensioner Using Secondary Chain Hold Down

    Courtesy of FORD MOTOR CO.
85. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
    • Align the colored links with the timing marks.
      Fig 82: Aligning Colored Links With Timing Marks

      Courtesy of FORD MOTOR CO.
86. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

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

    Fig 83: Aligning Holes In VCT Assemblies With Dowel Pins In Camshafts

    Courtesy of FORD MOTOR CO.
87. Install the 2 new RH VCT bolts and tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
      Fig 84: Locating RH VCT Bolts

      Courtesy of FORD MOTOR CO.
88. Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.
      Fig 85: Compressing RH Secondary Timing Chain Tensioner Using Secondary Chain Hold Down

      Courtesy of FORD MOTOR CO.
89. Compress the LH secondary chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
    Fig 86: Compressing LH Secondary Timing Chain Tensioner Using Secondary Chain Hold Down

    Courtesy of FORD MOTOR CO.
90. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
    • Align the colored links with the timing marks.
      Fig 87: Aligning Colored Links With Timing Marks

      Courtesy of FORD MOTOR CO.
91. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

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

    Fig 88: Aligning Holes In VCT Assemblies With Dowel Pins In Camshafts

    Courtesy of FORD MOTOR CO.
92. Install the 2 new LH VCT bolts and tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
      Fig 89: Locating LH VCT Bolts

      Courtesy of FORD MOTOR CO.
93. Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.
      Fig 90: Compressing LH Secondary Timing Chain Tensioner Using Secondary Chain Hold Down

      Courtesy of FORD MOTOR CO.

    All engines 

94. Install the upper LH primary timing chain guide and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 91: Locating Upper LH Primary Timing Chain Guide And Bolt

      Courtesy of FORD MOTOR CO.
95. Rotate the crankshaft 60 degrees to the Top Dead Center (TDC) position (crankshaft dowel at 11 o'clock).
    Fig 92: Locating Crankshaft Dowel Pin At 11 O'Clock Position

    Courtesy of FORD MOTOR CO.
96. Install the crankshaft timing chain sprocket with timing dot mark out.
    Fig 93: Locating Crankshaft Timing Chain Sprocket

    Courtesy of FORD MOTOR CO.
97. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.

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

    Fig 94: Aligning Primary Timing Chain Colored Links With Timing Marks On VCT Assemblies And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
98. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 95: Locating Bolts And Lower LH Primary Timing Chain Guide

      Courtesy of FORD MOTOR CO.
99. Install the primary timing chain tensioner arm.
    Fig 96: Identifying Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
100. Reset the primary timing chain tensioner.
     1. Release the ratchet detent.
     2. Using a soft-jawed vise, compress the ratchet plunger.
     3. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a suitable lockpin.
        Fig 97: Resetting Primary Timing Chain Tensioner

        Courtesy of FORD MOTOR CO.
101. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

     Install the primary timing chain tensioner and the 2 bolts.

     • Tighten to 10 Nm (89 lb-in).
     • Remove the lockpin.
       Fig 98: Locating Primary Tensioner Bolts And Lockpin

       Courtesy of FORD MOTOR CO.
102. As a post-check, verify correct alignment of all timing marks.
     • There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
     • There is 35 links in between RH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
       Fig 99: Checking Correct Alignment Of All Timing Marks

       Courtesy of FORD MOTOR CO.
103. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
     NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
     NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

     Install the LH intake VCT oil control solenoid and the bolt.

     • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
       Fig 100: Locating Bolt And LH Intake VCT Oil Control Solenoid

       Courtesy of FORD MOTOR CO.
104. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
     NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
     NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

     Install the RH intake VCT oil control solenoid and the bolt.

     • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
       Fig 101: Locating Bolt And RH Intake VCT Oil Control Solenoid

       Courtesy of FORD MOTOR CO.
105. Remove the RH Camshaft Holding Tool.
     Fig 102: Identifying RH Camshaft Holding Tool

     Courtesy of FORD MOTOR CO.
106. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages.
     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 45 degrees.
       Fig 103: Locating Bolts And RH Valve Train Oil Tube

       Courtesy of FORD MOTOR CO.
107. Remove the LH Camshaft Holding Tool.
     Fig 104: Identifying LH Camshaft Holding Tool

     Courtesy of FORD MOTOR CO.
108. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages.
     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 45 degrees.
       Fig 105: Locating Bolts And LH Valve Train Oil Tube

       Courtesy of FORD MOTOR CO.
109. NOTE: Use Spindle Bearing Installer 205-149 to install the seal.

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

     Fig 106: Installing Front Cover Radial Seal From Rear Side Of Front Cover

     Courtesy of FORD MOTOR CO.
110. 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: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this procedure can cause engine oil leakage.
     NOTE: The engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 must be installed within 10 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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

     • Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
       Fig 107: Applying RTV Silicone To Areas Of Oil Pan-To-Cylinder Block Joints And Cylinder Head-To-Cylinder Block Joints

       Courtesy of FORD MOTOR CO.
111. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

     Install the engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 and tighten in the sequence shown in illustration in 3 stages:

     • Stage 1: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 in sequence to 10 Nm (89 lb-in).
     • Stage 2: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19 and 20 in sequence to 20 Nm (177 lb-in) then an additional 45 degrees.
     • Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees.
       Fig 108: Identifying Engine Front Cover Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
112. Install the remaining 12 engine front cover bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 16, 22 and tighten in the sequence shown in illustration in 3 stages:
     • Stage 1: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, and 16 to 10 Nm (89 lb-in).
     • Stage 2: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, and 16 to 20 Nm (177 lb-in) then an additional 45 degrees.
     • Stage 3: Tighten bolt 22 to 10 Nm (89 lb-in) then an additional 45 degrees.
       Fig 109: Identifying Engine Front Cover Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
113. Using a new gasket, install the oil filter adapter and the 5 bolts and tighten in sequence shown in illustration.
     • Tighten to 10 Nm (89 lb-in) then an additional 45 degrees.
       Fig 110: Identifying Oil Filter Adapter Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
114. NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

     Install the new oil cooler and the oil cooler insert bolt.

     • Tighten to 58 Nm (43 lb-ft).
       Fig 111: Locating Threaded Shaft

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

       Courtesy of FORD MOTOR CO.
116. Install the new the Cylinder Head Temperature (CHT) sensor.
     • Tighten to 11 Nm (97 lb-in).
       Fig 113: Locating CHT Sensor

       Courtesy of FORD MOTOR CO.
117. NOTE: Lubricate the 2 CMP sensor O-ring seals with clean engine oil.

     Install the 2 LH CMP sensors and the bolts.

     • Tighten to 10 Nm (89 lb-in).
       Fig 114: Locating LH CMP Sensors And Bolts

       Courtesy of FORD MOTOR CO.
118. Install the 8 new RH exhaust manifold studs.
     • Tighten to 12 Nm (106 lb-in).
       Fig 115: Locating RH Exhaust Manifold Studs

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

     Using a new gasket, install the RH exhaust manifold and the 8 new nuts. Tighten in 2 stages in the sequence shown in illustration.

     • Stage 1: Tighten to 19 Nm (168 lb-in).
     • Stage 2: Tighten to 25 Nm (18 lb-ft).
       Fig 116: Identifying RH Exhaust Manifold Nuts Tightening Sequence

       Courtesy of FORD MOTOR CO.
120. NOTE: Installation of new seals is only required if damaged seals were removed.

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

     Fig 117: Installing Spark Plug Tube Seals

     Courtesy of FORD MOTOR CO.
121. NOTE: Installation of new seals is only required if damaged seals were removed.

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

     Fig 118: Installing VCT Solenoid Seal

     Courtesy of FORD MOTOR CO.
122. NOTE: Failure to use the correct Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
     NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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

     Fig 119: Applying RTV Silicone On Engine Front Cover-To-RH Cylinder Head Joints

     Courtesy of FORD MOTOR CO.
123. Using a new gasket, install the RH valve cover and tighten the 12 stud bolts in the sequence shown in illustration.
     • Tighten to 10 Nm (89 lb-in).
       Fig 120: Identifying RH Valve Cover Stud Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
124. Ensure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
     Fig 121: Locating VCT Seals In Valve Cover

     Courtesy of FORD MOTOR CO.
125. NOTE: Lubricate the 2 CMP sensor O-ring seals with clean engine oil.

     Install the 2 RH CMP sensors and the bolts.

     • Tighten to 7 Nm (62 lb-in).
       Fig 122: Locating Bolts And CMP Sensors

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

     Install the 3 RH spark plugs.

     • Tighten to 15 Nm (133 lb-in).
127. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
     • To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
       Fig 123: Inspecting Coil Seals For Rips, Nicks Or Tears

       Courtesy of FORD MOTOR CO.
128. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts.
     • Tighten to 7 Nm (62 lb-in) then an additional 45 degrees.
       Fig 124: Locating RH Ignition Coil-On-Plugs And Bolts

       Courtesy of FORD MOTOR CO.
129. Install the 8 new LH exhaust manifold studs.
     • Tighten to 12 Nm (106 lb-in).
       Fig 125: Locating LH Exhaust Manifold Studs

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

     Using a new gasket, install the LH exhaust manifold and 8 new nuts. Tighten in 2 stages in the sequence shown in illustration.

     • Stage 1: Tighten to 19 Nm (168 lb-in).
     • Stage 2: Tighten to 25 Nm (18 lb-ft).
       Fig 126: Identifying LH Exhaust Manifold Nuts Tightening Sequence

       Courtesy of FORD MOTOR CO.
131. NOTE: Installation of new seals is only required if damaged seals were removed.

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

     Fig 127: Installing Spark Plug Tube Seals

     Courtesy of FORD MOTOR CO.
132. NOTE: Installation of new seals is only required if damaged seals were removed.

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

     Fig 128: Installing VCT Solenoid Seal

     Courtesy of FORD MOTOR CO.
133. NOTE: Failure to use the correct Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
     NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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

     Fig 129: Applying RTV Silicone On Engine Front Cover-To-LH Cylinder Head Joints

     Courtesy of FORD MOTOR CO.
134. Using a new gasket, install the LH valve cover and tighten the 11 stud bolts in the sequence shown in illustration.
     • Tighten to 10 Nm (89 lb-in).
       Fig 130: Identifying LH Valve Cover Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
135. Ensure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
     Fig 131: Locating VCT Seals In Valve Cover

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

     Install the 3 LH spark plugs.

     • Tighten to 15 Nm (133 lb-in).
137. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
     • To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
       Fig 132: Inspecting Coil Seals For Rips, Nicks Or Tears

       Courtesy of FORD MOTOR CO.
138. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts.
     • Tighten to 7 Nm (62 lb-in) then an additional 45 degrees.
       Fig 133: Locating LH Ignition Coil-On-Plugs And Bolts

       Courtesy of FORD MOTOR CO.
139. Using new gaskets, install the fuel injection pump mounting plate and bolt.
     • Tighten finger-tight.
       Fig 134: Locating Fuel Injection Pump Mounting Plate And Bolt

       Courtesy of FORD MOTOR CO.
140. NOTE: Do not attempt to cut the lower Teflon® seal without pulling it away from the fuel injector or damage to the fuel injector may occur.
     NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

     Pull the Teflon® seal away from the fuel injector with narrow tip pliers.

     Fig 135: Pulling Teflon® Seal Away From Fuel Injector With Narrow Tip Pliers

     Courtesy of FORD MOTOR CO.
141. Carefully cut and discard the lower fuel injector Teflon® seals.
     Fig 136: Cutting Lower Fuel Injector Teflon Seal

     Courtesy of FORD MOTOR CO.
142. Place the Teflon® Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
     Fig 137: Placing Teflon® Seal Sizer, Knurled Side Out, Over Fuel Injector Tip

     Courtesy of FORD MOTOR CO.
143. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

     Install the new lower Teflon® seals on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tip.

     Fig 138: Exploded View Of Engine Lubrication Components

     Courtesy of FORD MOTOR CO.
144. NOTE: Once the Teflon® seal is installed on the Arbor, it should immediately be installed onto the fuel injector to avoid excessive expansion of the seal.

     Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals off of the Arbor and into the groove on the fuel injector.

     Fig 139: Sliding Teflon® Seals Off Of Arbor And Into Groove On Fuel Injector

     Courtesy of FORD MOTOR CO.
145. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the seal.

     Slide the Teflon® Seal Sizer off the end of the fuel injector to size the seal.

     Fig 140: Sliding Teflon® Seal Sizer Off End Of Fuel Injector To Size Seal

     Courtesy of FORD MOTOR CO.
146. 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-rings.
     NOTE: Apply clean engine oil to the 6 new upper fuel injector O-ring seals.
     NOTE: Inspect the fuel injector support disk and replace if necessary.

     Install the 6 new upper fuel injector O-ring seals.

     Fig 141: Locating Upper Fuel Injector O-Rings

     Courtesy of FORD MOTOR CO.
147. Install the 6 new fuel injector clips.
     Fig 142: Locating Fuel Injector Clip

     Courtesy of FORD MOTOR CO.
148. NOTE: RH shown in illustration, LH similar.
     NOTE: The anti rotation device on the fuel injector has to slip into the groove of the fuel rail cup.

     Install the 6 fuel injectors into the fuel rails and connect the fuel injector electrical connector.

     Fig 143: Locating Fuel Injector Electrical Connectors And Fuel Injector Wire Harness

     Courtesy of FORD MOTOR CO.
149. NOTE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.
     NOTE: Tighten the bolts using a method that draws the fuel rail evenly to the cylinder head, preventing a rocking motion.

     Install the RH fuel rail assembly and the 6 new bolts. Tighten in 3 stages in the sequence shown in illustration.

     • Stage 1: Push down on the fuel rail face above the fuel injectors.
     • Stage 2: Tighten to 10 Nm (89 lb-in).
     • Stage 3: Tighten an additional 45 degrees.
       Fig 144: Identifying RH Fuel Rail Assembly Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
150. NOTE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.
     NOTE: Tighten the bolts using a method that draws the fuel rail evenly to the cylinder head, preventing a rocking motion.

     Install the LH fuel rail assembly and the 6 new bolts. Tighten in 3 stages in the sequence shown in illustration.

     • Stage 1: Push down on the fuel rail face above the fuel injectors.
     • Stage 2: Tighten to 10 Nm (89 lb-in).
     • Stage 3: Tighten an additional 45 degrees.
       Fig 145: Identifying LH Fuel Rail Assembly Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
151. NOTE: Apply clean engine oil to the threads of the 2 high-pressure fuel tube flare nuts.

     Position the new high-pressure fuel tube and hand start the flare nuts in 2 stages.

     • Stage 1: Hand tighten the high-pressure fuel tube-to-RH fuel rail flare nut.
     • Stage 2: Hand tighten the high-pressure fuel tube-to-LH fuel rail flare nut.
       Fig 146: Locating High-Pressure Fuel Tube Assembly And Flare Nuts

       Courtesy of FORD MOTOR CO.
152. Loosely install the bolt for the high-pressure fuel tube.
     Fig 147: Locating High-Pressure Fuel Tube Bolt

     Courtesy of FORD MOTOR CO.
153. Connect the high-pressure fuel tube to the fuel rails. Tighten in 6 stages.
     • Stage 1: Tighten the high-pressure fuel tube-to-RH fuel rail flare nut to 15 Nm (133 lb-in).
     • Stage 2: Tighten an additional 30 degrees.
     • Stage 3: Tighten to 32 Nm (24 lb-ft).
     • Stage 4: Tighten the high-pressure fuel tube-to-LH fuel rail flare nut to 15 Nm (133 lb-in).
     • Stage 5: Tighten an additional 30 degrees.
     • Stage 6: Tighten to 32 Nm (24 lb-ft).
       Fig 148: Locating High-Pressure Fuel Tube Assembly And Flare Nuts

       Courtesy of FORD MOTOR CO.
154. Tighten the bolt for the high-pressure fuel tube.
     • Tighten the bolt to 10 Nm (89 lb-in) then an additional 45 degrees.
       Fig 149: Locating High-Pressure Fuel Tube Bolt

       Courtesy of FORD MOTOR CO.
155. Using new gaskets, install the coolant crossover manifold assembly and the 3 bolts.
     • Tighten to 10 Nm (89 lb-in) then an additional 45 degrees.
       Fig 150: Locating Coolant Crossover Manifold Assembly And Bolts

       Courtesy of FORD MOTOR CO.
156. NOTE: Lubricate the O-ring seal with clean engine coolant.

     Using new O-ring seals, install the coolant inlet pipe.

     Fig 151: Locating Coolant Inlet Pipe O-Ring Seals

     Courtesy of FORD MOTOR CO.
157. NOTE: Lubricate the O-ring seal with clean engine coolant.

     Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7 bolts and tighten in 2 stages in the sequence shown in illustration.

     • Stage 1: Tighten to 10 Nm (89 lb-in).
     • Stage 2: Tighten an additional 45 degrees.
       Fig 152: Identifying Coolant Pump Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
158. Install the coolant pump pulley and the 4 bolts.
     • Tighten to 24 Nm (18 lb-ft).
       Fig 153: Locating Coolant Pump Pulley And Bolts

       Courtesy of FORD MOTOR CO.
159. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.

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

     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 45 degrees.
       Fig 154: Identifying Thermostat Housing Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
160. NOTE: Apply thread sealant with PTFE to the threads prior to installing the cylinder block drain plug.

     Install the RH cylinder block drain plug.

     • Tighten to 20 Nm (177 lb-in) then an additional 180 degrees.
       Fig 155: Locating RH Cylinder Block Drain Plug

       Courtesy of FORD MOTOR CO.
161. NOTE: Apply thread sealant with PTFE to the threads prior to installing the cylinder block drain plug.

     Install the LH cylinder block drain plug.

     • Tighten the cylinder block drain plug to 10 Nm (89 lb-in) then an additional 720 degrees.
       Fig 156: Locating LH Cylinder Block Drain Plug

       Courtesy of FORD MOTOR CO.
162. Install the accessory drive belt tensioner and the 2 bolts.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 157: Locating Accessory Drive Belt Tensioner And Bolts

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

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

     Fig 158: Installing Crankshaft Front Seal Using Front Crankshaft Seal Installer And Crankshaft Vibration Damper Installer

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

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

     Fig 159: Installing Crankshaft Pulley

     Courtesy of FORD MOTOR CO.
166. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
     • Stage 1: Tighten to 120 Nm (89 lb-ft).
     • Stage 2: Loosen one full turn.
     • Stage 3: Tighten to 50 Nm (37 lb-ft).
     • Stage 4: Tighten an additional 90 degrees.
       Fig 160: Installing Crankshaft Pulley Washer And Bolt Using Strap Wrench

       Courtesy of FORD MOTOR CO.
167. Position the engine wire harness on the engine. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
168. Connect the wire harness retainer and install the tie strap.
     Fig 161: Locating Tie Strap And Wire Retainer On Valve Cover

     Courtesy of FORD MOTOR CO.
169. Connect the 2 RH CMP electrical connectors.
     Fig 162: Locating Camshaft Position Sensor Electrical Connectors

     Courtesy of FORD MOTOR CO.
170. Connect the 3 RH ignition coil-on-plug electrical connectors.
     Fig 163: Locating RH Ignition Coil-On-Plug Electrical Connectors

     Courtesy of FORD MOTOR CO.
171. Connect the 2 RH VCT solenoid electrical connectors. Install the tie strap.
     Fig 164: Locating RH VCT Solenoid Electrical Connectors And Tie Strap

     Courtesy of FORD MOTOR CO.
172. Connect the CHT sensor electrical connector. Install the ground stud bolt and the tie strap.
     • Tighten to 10 Nm (89 lb-in) then an additional 45 degrees.
       Fig 165: Locating Cylinder Head Temperature Sensor Electrical Connector, Ground Stud Bolt And Tie Strap

       Courtesy of FORD MOTOR CO.
173. Install the CMP heat shield, bolt and the nut. Connect the wire retainer.
     • Tighten the bolt to 10 Nm (89 lb-in).
     • Tighten the nut to 10 Nm (89 lb-in).
       Fig 166: Locating Wire Retainer, Nut, Bolt And CMP Heat Shield

       Courtesy of FORD MOTOR CO.
174. Connect the 2 fuel charge harness and the Fuel Rail Pressure (FRP) electrical connectors. Connect the KS sensor electrical connector.
     Fig 167: Locating Knock Sensor Electrical Connector, Fuel Charge Harness And Fuel Rail Pressure Electrical Connectors

     Courtesy of FORD MOTOR CO.
175. Connect the 2 LH CMP sensor electrical connectors. Install the ground stud bolt. Install the CKP wire retainer.
     • Tighten to 10 Nm (89 lb-in) then an additional 45 degrees.
       Fig 168: Locating LH Camshaft Position (CMP) Sensor Electrical Connectors, Crankshaft Position (CKP) Wire Retainer And Ground Stud Bolt

       Courtesy of FORD MOTOR CO.
176. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
177. Connect the CKP sensor electrical connector.
     Fig 169: Locating Crankshaft Position (CKP) Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
178. Install the wiring harness grommet.
     Fig 170: Locating Wiring Harness Grommet

     Courtesy of FORD MOTOR CO.
179. Install the wiring harness retainer stud bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 171: Locating Wiring Harness Retainer Stud Bolt

       Courtesy of FORD MOTOR CO.
180. Install the CKP heat shield, the nut and the bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 172: Locating Crankshaft Position Heat Shield, Bolt And Nut

       Courtesy of FORD MOTOR CO.
181. Connect the 3 LH ignition coil-on-plug electrical connectors.
     Fig 173: Locating LH Ignition Coil-On-Plug Electrical Connectors

     Courtesy of FORD MOTOR CO.
182. Connect the Engine Oil Pressure (EOP) switch electrical connector.
     • Attach the EOP switch wiring harness retainer to the cylinder head.
       Fig 174: Locating EOP Switch Wiring Harness Retainer And Engine Oil Pressure (EOP) Switch Electrical Connector

       Courtesy of FORD MOTOR CO.
183. Connect the 2 LH VCT solenoid electrical connectors. Install the tie strap.
     Fig 175: Locating LH Variable Camshaft Timing (VCT) Solenoid Electrical Connectors And Tie Strap

     Courtesy of FORD MOTOR CO.
184. Install the engine oil level indicator.
     Fig 176: Locating Oil Level Indicator

     Courtesy of FORD MOTOR CO.
185. NOTE: Make sure the oil tube filter screen is free of contaminants prior to the installation of the vacuum pump or damage to components may occur.

     Visual check. Install a new gasket if necessary.

     Fig 177: Checking Gasket

     Courtesy of FORD MOTOR CO.
186. NOTE: If the brake vacuum pump is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Failure to follow this procedure can cause future oil leakage.
     NOTE: Make sure the mating surfaces are clean and free of foreign material.

     Apply a bead of the specified diameter from the specified tube.

     Fig 178: Applying Bead Of Sealant

     Courtesy of FORD MOTOR CO.
187. NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.

     Visual check.

     • Tighten in the sequence shown to 10 Nm (89 lb-in) then an additional 45 degrees.
       Fig 179: Identifying Brake Vacuum Pump Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
188. Install the LH engine support insulator-to-cylinder block bracket and the 4 new bolts.
     • Tighten to 63 Nm (46 lb-ft).
       Fig 180: Locating LH Engine Support Insulator-To-Cylinder Block Bracket And Bolts

       Courtesy of FORD MOTOR CO.
189. Install the RH engine support insulator and the 4 new bolts.
     • For standard payload package, tighten to 63 Nm (46 lb-ft).
     • For heavy duty payload package, tighten to 77 Nm (57 lb-ft).
       Fig 181: Locating RH Engine Support Insulator Bolts

       Courtesy of FORD MOTOR CO.
190. Install the RH turbocharger mounting bracket and the 2 bolts.
     • Tighten finger-tight.
       Fig 182: Locating RH Turbocharger Mounting Bracket Bolts

       Courtesy of FORD MOTOR CO.
191. NOTE: Lubricate the cylinder block bore with clean engine oil.
     NOTE: Apply clean engine oil to the O-ring seal.
     NOTE: Make sure the turbocharger oil supply tube in positioned in the cylinder block during the installation of the turbocharger oil return tube.

     Using a new O-ring seal, install the RH turbocharger oil return tube.

     Fig 183: Locating RH Turbocharger Oil Return Tube

     Courtesy of FORD MOTOR CO.
192. NOTE: Install the RH turbocharger coolant return tube in the turbocharger prior to installation.

     Using a new turbocharger exhaust manifold gasket, install the RH turbocharger and the 3 bolts.

     • Tighten finger-tight.
       Fig 184: Locating RH Turbocharger Bolts

       Courtesy of FORD MOTOR CO.
193. Install the RH turbocharger mounting bracket bolt.
     • Tighten finger-tight.
       Fig 185: Locating RH Turbocharger Bracket Bolt

       Courtesy of FORD MOTOR CO.
194. Tighten the RH turbocharger mounting bolts.
     • Tighten to 32 Nm (24 lb-ft).
       Fig 186: Locating RH Turbocharger Bolts

       Courtesy of FORD MOTOR CO.
195. Tighten the RH turbocharger bracket bolt.
     • Tighten to 28 Nm (21 lb-ft).
       Fig 187: Locating RH Turbocharger Bracket Bolt

       Courtesy of FORD MOTOR CO.
196. NOTE: Turbocharger removed for clarity.

     Tighten the 2 turbocharger mounting bracket bolts.

     • Tighten to 10 Nm (89 lb-in).
       Fig 188: Locating Turbocharger Mounting Bracket Bolts

       Courtesy of FORD MOTOR CO.
197. Using a new turbocharger oil return tube gasket, install the 2 bolts at the turbocharger. Tighten in the following stages.
     • Stage 1: Install the bolt for the oil pressure tube side halfway.
     • Stage 2: Install the bolt for the oil drain tube side and tighten to 10 Nm (89 lb-in).
     • Stage 3: Tighten the bolt for the oil drain tube side an additional 30 degrees.
     • Stage 4: Tighten the bolt for the oil pressure tube side to 10 Nm (89 lb-in).
     • Stage 5: Tighten the bolt for the oil pressure tube side an additional 30 degrees.
       Fig 189: Locating RH Turbocharger Oil Return Tube And Bolts

       Courtesy of FORD MOTOR CO.
198. Install the RH turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages.
     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 30 degrees.
       Fig 190: Locating Turbocharger Oil Return Tube Bolt

       Courtesy of FORD MOTOR CO.
199. Install the bolt for the RH turbocharger coolant and oil tubes. Tighten in the following stages.
     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 30 degrees.
       Fig 191: Locating Bolt For RH Turbocharger Coolant And Oil Tubes

       Courtesy of FORD MOTOR CO.
200. Install the RH turbocharger coolant supply tube.
     Fig 192: Locating RH Turbocharger Coolant Supply Tube

     Courtesy of FORD MOTOR CO.
201. Install the LH turbocharger mounting bracket and the 2 bolts.
     • Tighten finger-tight.
       Fig 193: Locating LH Turbocharger Mounting Bracket Bolts

       Courtesy of FORD MOTOR CO.
202. NOTE: Lubricate the cylinder block bore with clean engine oil.
     NOTE: Apply clean engine oil to the O-ring seal.
     NOTE: Make sure the turbocharger oil supply tube in positioned in the cylinder block during the installation of the turbocharger oil return tube.

     Using a new O-ring seal, install the LH turbocharger oil return tube.

     Fig 194: Locating LH Turbocharger Oil Return Tube

     Courtesy of FORD MOTOR CO.
203. NOTE: Install the LH turbocharger coolant return tube in the turbocharger prior to installation.

     Using a new turbocharger exhaust manifold gasket, install the LH turbocharger and the 3 bolts.

     • Tighten finger-tight.
       Fig 195: Locating LH Turbocharger Bolts

       Courtesy of FORD MOTOR CO.
204. Install the LH turbocharger mounting bracket bolt.
     • Tighten finger-tight.
       Fig 196: Locating LH Turbocharger Bracket Bolt

       Courtesy of FORD MOTOR CO.
205. Tighten the LH turbocharger mounting bolts.
     • Tighten to 32 Nm (24 lb-ft).
       Fig 197: Locating LH Turbocharger Bolts

       Courtesy of FORD MOTOR CO.
206. Tighten the LH turbocharger bracket bolt.
     • Tighten to 28 Nm (21 lb-ft).
       Fig 198: Locating LH Turbocharger Bracket Bolt

       Courtesy of FORD MOTOR CO.
207. NOTE: Turbocharger removed for clarity.

     Tighten the 2 turbocharger mounting bracket bolts.

     • Tighten to 10 Nm (89 lb-in).
       Fig 199: Locating LH Turbocharger Mounting Bracket Bolts

       Courtesy of FORD MOTOR CO.
208. Using a new turbocharger oil return tube gasket, install the 2 bolts at the turbocharger. Tighten in the following stages.
     • Stage 1: Install the bolt for the oil pressure tube side halfway.
     • Stage 2: Install the bolt for the oil drain tube side and tighten to 10 Nm (89 lb-in).
     • Stage 3: Tighten the bolt for the oil drain tube side an additional 30 degrees.
     • Stage 4: Tighten the bolt for the oil pressure tube side to 10 Nm (89 lb-in).
     • Stage 5: Tighten the bolt for the oil pressure tube side an additional 30 degrees.
       Fig 200: Locating LH Turbocharger Oil Return Tube And Bolts

       Courtesy of FORD MOTOR CO.
209. Install the LH turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages.
     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 30 degrees.
       Fig 201: Locating Oil Turbocharger Oil Return Tube And Bolt

       Courtesy of FORD MOTOR CO.
210. Remove the bolt for the LH turbocharger coolant and oil tubes. Tighten in the following stages.
     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 30 degrees.
       Fig 202: Locating Bolt For LH Turbocharger Coolant And Oil Tubes

       Courtesy of FORD MOTOR CO.
211. Install the LH turbocharger coolant supply tube.
     Fig 203: Locating Turbocharger Coolant Supply Tube

     Courtesy of FORD MOTOR CO.
212. Install the wastegate hose assembly and 2 tie straps. Connect the turbocharger pressure regulator electrical connector.
     Fig 204: Locating Turbocharger Pressure Regulator Electrical Connector, Tie Straps And Wastegate Hose Assembly

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

     Position the wastegate hoses and install the 2 tie straps.

     Fig 205: Locating Tie Strap For Turbocharger Wastegate Hose

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

     Connect the 2 wastegate hoses at the turbochargers.

     Fig 206: Locating Turbocharger Wastegate Hose

     Courtesy of FORD MOTOR CO.
215. Install the RH PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
     Fig 207: Locating RH PCV Tube

     Courtesy of FORD MOTOR CO.
216. Install the LH crankcase vent tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
     Fig 208: Locating LH Crankcase Vent Tube

     Courtesy of FORD MOTOR CO.
217. Install the A/C compressor and the 3 bolts.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 209: Locating A/C Compressor And Bolts

       Courtesy of FORD MOTOR CO.
218. Install the Right Front Lifting Eye and the 2 bolts.
     • Tighten to 24 Nm (18 lb-ft).
       Fig 210: Locating Right Front Lift Eye And Bolts

       Courtesy of FORD MOTOR CO.
219. Using the Floor Crane and Engine Spreader Bar, remove the engine from the stand.
     Fig 211: Mounting Engine On Suitable Engine Stand Using Floor Crane And Engine Spreader Bar

     Courtesy of FORD MOTOR CO.

     Cast aluminum (early build) crankshaft rear seal retainer plate 

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

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

     Fig 212: Positioning Rear Main Seal Installer Onto End Of Crankshaft

     Courtesy of FORD MOTOR CO.
221. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
     Fig 213: Installing Crankshaft Rear Seal Using Rear Main Seal Installer And Handle

     Courtesy of FORD MOTOR CO.

     All vehicles 

222. Install the crankshaft sensor ring.
     Fig 214: Identifying Crankshaft Sensor Ring

     Courtesy of FORD MOTOR CO.
223. Install the spacer plate.
     Fig 215: Locating Spacer Plate

     Courtesy of FORD MOTOR CO.
224. Install the flexplate and the 8 bolts and tighten is sequence shown in illustration.
     • Tighten to 80 Nm (59 lb-ft).
       Fig 216: Identifying Flexplate Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.