Lower Engine Block (View 2)

All engines 

1. Using a hexagonal screwdriver, install the 6 piston oil cool valves.
   • Tighten to 4 Nm (35 lb-in).
2. NOTE: This step is for selecting the correct main bearings.
   NOTE: The #1 main bearing is at the front of the engine block.

   Select the crankshaft main bearings for each crankshaft journal.

   • Record the code that is on the cylinder block face.
   • Record the code that is on the crankshaft flange.
   • The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.
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 "M" and the crankshaft code letter is "M", the correct bearing grade for this main bearing is a "2" 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.
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 "N" and the crankshaft code letter is "H", the correct bearing grade for this main bearing is "2".
   • Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
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 SPECIFICATIONS .
   • Remove the bolts and the rod cap.
     • Discard the connecting rod cap bolts.
       Fig 1: Identifying Connecting Rod Large End Bore

       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 SPECIFICATIONS .
   Fig 2: Locating Crankshaft Connecting Rod Bearing Journal Diameters

   Courtesy of FORD MOTOR CO.
8. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
   Fig 3: Connecting Rod Large End Bore Selection 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 4: Locating Crankshaft Main Bearing Caps

   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 5: 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 6: 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 7: 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 8: Locating Crankshaft 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 9: Locating No. 1, No. 2 And No. 3 Main Bearing Caps

    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 10: Locating Main Bearing Cap Tab And Cutout

    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 11: 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 12: Identifying Main 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 13: Identifying 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 14: Measuring Crankshaft End Play Using Dial Indicator Gauge And 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 15: Locating Connecting Rod And Cap

      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 16: 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 17: 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 18: Locating 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 19: Identifying Bearing Cap Support Brace And 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 10 minutes of sealant application.
    NOTE: The stamped steel 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.

29. 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).
30. Install the oil pump and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
31. 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).
32. 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.

33. 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.
34. 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 20: Identifying Oil Pan And Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
35. Laterally align the oil pan to the block. Make sure the oil pan is flush with the block at these 2 points.
    Fig 21: Locating Oil Pan With Block At Points

    Courtesy of FORD MOTOR CO.
36. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration.
    • Tighten to 3 Nm (27 lb-in).
      Fig 22: Identifying Oil Pan And Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
37. 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 23: Identifying Oil Pan Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
38. Install the Knock Sensor (KS) and the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 24: Locating Knock Sensor And Bolts

      Courtesy of FORD MOTOR CO.
39. 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 25: Identifying RH Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
40. Install the new M6 bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 26: Locating Cylinder Head M6 Bolt

      Courtesy of FORD MOTOR CO.
41. 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 27: Identifying Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
42. Install the new M6 bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Locating Cylinder Head M6 Bolt

      Courtesy of FORD MOTOR CO.
43. 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 29: Locating Cylinder Head Valve Tappet

    Courtesy of FORD MOTOR CO.
44. 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.

45. 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 30: Locating Camshafts Onto RH Cylinder Head In Neutral Position

    Courtesy of FORD MOTOR CO.
46. 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 31: Locating Camshaft Seals Gaps

    Courtesy of FORD MOTOR CO.
47. 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.
48. Loosen the 4 camshaft caps bolts.
49. 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.
50. 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 32: Measuring Valve Tappet Clearance Using Feeler Gauge

    Courtesy of FORD MOTOR CO.
51. 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.

52. 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.
53. Remove the 3 bolts and the RH valve train oil tube.
54. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown in illustration.
55. 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.

56. 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 33: Locating Camshafts Onto LH Cylinder Head In Neutral Position

    Courtesy of FORD MOTOR CO.
57. 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 34: Locating Camshaft Seal Gaps

    Courtesy of FORD MOTOR CO.
58. 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.
59. Loosen the 4 camshaft caps bolts.
60. 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.
61. 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 35: Measuring Valve Tappet Clearance Using Feeler Gauge

    Courtesy of FORD MOTOR CO.
62. Remove the 3 bolts and the LH valve train oil tube.
63. Rotate the LH camshafts to the TDC  position as shown in illustration.
64. 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.

65. 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.
66. Install the RH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

    Engines with secondary timing chain tensioner removed 

    NOTE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed or damage to the engine may occur.
67. 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.

68. Install the RH secondary timing chain tensioner shoe.
69. Remove and discard the RH secondary timing chain tensioner shipping clip.
70. 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.
71. 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.

72. 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.
73. 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.
74. 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.
75. 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.

76. Install the LH secondary timing chain tensioner shoe.
77. Remove and discard the LH secondary timing chain tensioner shipping clip.
78. Assemble the 2 LH VCT  assemblies and the LH secondary timing chain.
    • Align the colored links with the timing marks.
79. 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.

80. 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.
81. 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.
82. 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.

    Engines with secondary timing chain tensioner not removed 

83. Compress the RH secondary chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
84. 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.
85. 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.

86. 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.
87. 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.
88. Compress the LH secondary chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
89. Assemble the 2 LH VCT  assemblies and the LH secondary timing chain.
    • Align the colored links with the timing marks.
90. 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.

91. 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.
92. Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.

    All engines 

93. Install the upper LH primary timing chain guide and the bolt.
    • Tighten to 10 Nm (89 lb-in).
94. Rotate the crankshaft 60 degrees to the Top Dead Center (TDC) position (crankshaft dowel at 11 o'clock).
95. Install the crankshaft timing chain sprocket with timing dot mark out.
96. 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 36: Aligning Primary Timing Chain Colored Links With Timing Marks On VCT Assemblies And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
97. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
98. Install the primary timing chain tensioner arm.
99. 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.
100. 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.
101. As a post-check, verify correct alignment of all timing marks.
     • There are 48 links in between the RH intake VCT  assembly colored link (1) and the LH intake VCT  assembly colored link (2).
     • There are 35 links in between LH intake VCT  assembly colored link (2) and the 2 crankshaft sprocket links (3).
102. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT  oil control solenoid, inspect the bore and VCT  oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
     NOTE: A slight twisting motion will aid in the installation of the VCT  oil control solenoid.
     NOTE: Keep the VCT  oil control solenoid clean of dirt and debris.

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

     • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
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 RH intake VCT  oil control solenoid and the bolt.

     • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
104. Remove the RH Camshaft Holding Tool.
105. 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.
106. Remove the LH Camshaft Holding Tool.
107. 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.
108. 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.

109. 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.
110. 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 37: Identifying Engine Front Cover Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
111. 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 38: Identifying Engine Front Cover Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
112. 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 39: Identifying Oil Filter Adapter Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
113. 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).
114. Install the Crankshaft Position (CKP) sensor and install the bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 40: Locating CKP Sensor And Bolt

       Courtesy of FORD MOTOR CO.
115. Install the new the Cylinder Head Temperature (CHT) sensor.
     • Tighten to 11 Nm (97 lb-in).
116. 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).
117. Install the 8 new RH exhaust manifold studs.
     • Tighten to 12 Nm (106 lb-in).
118. 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).
119. 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.

120. 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).

121. 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.

122. 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).
123. 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.
124. 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).
125. 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).
126. 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 41: Locating Coil Seals Inspection Area

       Courtesy of FORD MOTOR CO.
127. 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.
128. Install the 8 new LH exhaust manifold studs.
     • Tighten to 12 Nm (106 lb-in).
129. 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).
130. 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.

131. 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).

132. 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.

133. 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).
134. 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.
135. 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).
136. 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 42: Locating Coil Seals Inspection Area

       Courtesy of FORD MOTOR CO.
137. 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.
138. Using new gaskets, install the fuel injection pump mounting plate and bolt.
     • Tighten finger-tight.
139. 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 43: Locating Lower Teflon Seal

     Courtesy of FORD MOTOR CO.
140. Carefully cut and discard the lower fuel injector Teflon® seals.
     Fig 44: Cutting Lower Fuel Injector Teflon Seal

     Courtesy of FORD MOTOR CO.
141. Place the Teflon® Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
     Fig 45: Placing Teflon® Seal Sizer, Knurled Side Out, Over Fuel Injector Tip Fuel Injector Seal

     Courtesy of FORD MOTOR CO.
142. 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 46: Installing Lower Teflon® Seals On Narrow End Of Arbor

     Courtesy of FORD MOTOR CO.
143. 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 47: Sliding Teflon® Seals Off Arbor And Fuel Injector Groove

     Courtesy of FORD MOTOR CO.
144. 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 48: Sliding Teflon® Seal Sizer Off End Of Fuel Injector

     Courtesy of FORD MOTOR CO.
145. 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 49: Locating Upper Fuel Injector O-Ring Seal

     Courtesy of FORD MOTOR CO.
146. Install the 6 new fuel injector clips.
     Fig 50: Locating Fuel Injector Clip

     Courtesy of FORD MOTOR CO.
147. 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 51: Locating Fuel Injector Electrical Connectors And Fuel Injector Wire Harness

     Courtesy of FORD MOTOR CO.
148. 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 52: Identifying RH Fuel Rail Assembly Bolts Tightening Sequence

       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 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 53: Identifying LH Fuel Rail Assembly Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
150. 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.
151. Loosely install the bolt for the high-pressure fuel tube.
152. 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).
153. Tighten the bolt for the high-pressure fuel tube.
     • Tighten the bolt to 10 Nm (89 lb-in) then an additional 45 degrees.
154. 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.
155. NOTE: Lubricate the O-ring seal with clean engine coolant.

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

156. 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 54: Identifying Coolant Pump Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
157. Install the coolant pump pulley and the 4 bolts.
     • Tighten to 24 Nm (18 lb-ft).
158. 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 55: Identifying Thermostat Housing Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
159. 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.
160. 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.
161. Install the accessory drive belt tensioner and the 2 bolts.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 56: Locating Accessory Drive Belt Tensioner And Bolts

       Courtesy of FORD MOTOR CO.
162. 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 57: Installing Crankshaft Front Seal

     Courtesy of FORD MOTOR CO.
163. Lubricate the crankshaft front seal inner lip with clean engine oil.
164. 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 58: Installing Crankshaft Pulley

     Courtesy of FORD MOTOR CO.
165. 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 59: Installing Crankshaft Pulley Washer And Bolt

       Courtesy of FORD MOTOR CO.
166. Position the engine wire harness on the engine. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
167. Connect the wire harness retainer and install the tie strap.
168. Connect the 2 RH CMP  electrical connectors.
169. Connect the 3 RH ignition coil-on-plug electrical connectors.
170. Connect the 2 RH VCT  solenoid electrical connectors. Install the tie strap.
171. 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.
172. 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).
173. Connect the 2 fuel charge harness and the Fuel Rail Pressure (FRP) electrical connectors. Connect the KS  sensor electrical connector.
174. 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.
175. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
176. Connect the CKP  sensor electrical connector.
     Fig 60: Locating CKP Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
177. Install the wiring harness grommet.
     Fig 61: Locating Wiring Harness Grommet

     Courtesy of FORD MOTOR CO.
178. Install the wiring harness retainer stud bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 62: Locating Wiring Harness Retainer Stud Bolt

       Courtesy of FORD MOTOR CO.
179. Install the CKP  heat shield, the nut and the bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 63: Locating CKP Heat Shield Nut And Bolt

       Courtesy of FORD MOTOR CO.
180. Connect the 3 LH ignition coil-on-plug electrical connectors.
181. Connect the Engine Oil Pressure (EOP) switch electrical connector.
     • Attach the EOP  switch wiring harness retainer to the cylinder head.
182. Connect the 2 LH VCT  solenoid electrical connectors. Install the tie strap.
183. Install the engine oil level indicator.
184. 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.

185. 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.

186. NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.

     Visual check.

     • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in) then an additional 45 degrees.
187. Install the LH engine support insulator-to-cylinder block bracket and the 4 new bolts.
     • Tighten to 63 Nm (46 lb-ft).
188. 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).
189. 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.

190. 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.
191. Tighten the RH turbocharger mounting bolts.
     • Tighten to 32 Nm (24 lb-ft).
192. 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.
193. 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.
194. 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.
195. Install the RH turbocharger coolant supply tube.
196. 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.

197. 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.
198. Tighten the LH turbocharger mounting bolts.
     • Tighten to 32 Nm (24 lb-ft).
199. 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.
200. 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.
201. 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.
202. Install the LH turbocharger coolant supply tube.
203. Install the wastegate hose assembly and 2 tie straps. Connect the turbocharger pressure regulator electrical connector.
204. NOTE: LH shown in illustration, RH similar.

     Position the wastegate hoses and install the 2 tie straps.

205. NOTE: LH shown in illustration, RH similar.

     Connect the 2 wastegate hoses at the turbochargers.

206. Install the RH PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
207. Install the LH crankcase vent tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
208. Install the A/C compressor and the 3 bolts.
     • Tighten to 25 Nm (18 lb-ft).
209. Using part of the Engine Lifting Bracket and a chain, assemble the Engine Spreader Bar as shown in illustration.
210. NOTE: Use a commercially available quick link on the right side between the lifting eye and the spreader bar.

     Using the Floor Crane and Engine Spreader Bar, remove the engine from the stand.

     Fig 64: Removing Engine From Stand Using Floor Crane And Engine Spreader Bar

     Courtesy of FORD MOTOR CO.
211. Install the crankshaft sensor ring.
212. Install the spacer plate.
     Fig 65: Locating Spacer Plate

     Courtesy of FORD MOTOR CO.
213. Install the flexplate and the 8 bolts and tighten is sequence shown in illustration.
     • Tighten to 80 Nm (59 lb-ft).
       Fig 66: Identifying Flexplate Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.