Lower Engine Block (View 2)

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

Courtesy of FORD MOTOR CO.

All engines 

1. 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.
2. 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.
3. 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.
4. 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.
5. Measure the connecting rod large end bore in 2 directions.
   • Remove the bolts and the rod cap.
     • Discard the connecting rod cap bolts.
       Fig 2: Identifying Connecting Rod Large End Bore Measuring Position

       Courtesy of FORD MOTOR CO.
6. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
   Fig 3: Identifying Crankshaft Connecting Rod Bearing Journal Diameters

   Courtesy of FORD MOTOR CO.
7. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
   Fig 4: Connecting Rod Bearings Selection Chart

   Courtesy of FORD MOTOR CO.
8. 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 5: Locating Crankshaft Main Bearings

   Courtesy of FORD MOTOR CO.
9. 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 6: Locating Crankshaft Onto Upper Main Bearings

   Courtesy of FORD MOTOR CO.
10. 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 7: Installing Rear Crankshaft Upper Thrust Washer At Back Of No. 4 Rear Bulkhead

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

    Fig 8: Installing Front Crankshaft Upper Thrust Washer At Front Of No. 4 Rear Bulkhead

    Courtesy of FORD MOTOR CO.
12. 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 9: Locating Crankshaft Bearings Cap

    Courtesy of FORD MOTOR CO.
13. 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 10: Locating Bearing Caps And Mounting Bolt

    Courtesy of FORD MOTOR CO.
14. 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 11: Aligning Lower Crankshaft Thrust Washer Tab With Cutout In No. 4 Rear Main Bearing Cap

    Courtesy of FORD MOTOR CO.
15. 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 12: Locating Main Bearing Cap No. 4

    Courtesy of FORD MOTOR CO.
16. Loosen the No. 4 main bearing cap bolts.
17. 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 the sequence shown below in 2 stages:

    • Stage 1: Tighten fasteners 1 through 8 to 33 Nm (24 lb-ft).
    • Stage 2: Tighten fasteners 1 through 8 an additional 135 degrees.
      Fig 13: Identifying Main Bearing Mounting Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
18. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown below in 2 stages:
    • Stage 1: Tighten fasteners 1 through 8 to 24 Nm (18 lb-ft).
    • Stage 2: Tighten fasteners 1 through 8 an additional 180 degrees.
      Fig 14: Identifying Main Bearing Cap Side Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
19. 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 15: Measuring Crankshaft End Play Using Dial Indicator Gauge With Holding Fixture

      Courtesy of FORD MOTOR CO.
20. 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 16: Locating Connecting Rod And Cap

      Courtesy of FORD MOTOR CO.
21. 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 17: Identifying Piston Rings End Gap Position

       Courtesy of FORD MOTOR CO.
22. 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.
    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 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES - 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 18: Installing Piston And Connecting Rod Using Piston Ring Compressor

    Courtesy of FORD MOTOR CO.
23. Seat the connecting rod on the crankshaft journal.
24. 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 19: Locating Connecting Rod Cap And Bolts

      Courtesy of FORD MOTOR CO.
25. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
26. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown below in 2 steps.
    • Stage 1: Tighten fasteners to 20 Nm (177 lb-in).
    • Stage 2: Tighten fasteners an additional 180 degrees.
      Fig 20: Identifying Bearing Cap Support Brace Mounting Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
27. 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.

    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 21: Locating Sealant Applying Area On Crankshaft Rear Seal Retainer

    Courtesy of FORD MOTOR CO.
28. NOTE: Lubricate the crankshaft rear seal with clean engine oil.
    NOTE: Use the 2 handles during installation to avoid touching the sealant.

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

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

32. 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.
33. 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 22: Identifying Oil Pan Mounting Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
34. Laterally align the oil pan to the block. Make sure the oil pan is flush with the block at these 2 points.
    Fig 23: Locating Oil Pan Seal

    Courtesy of FORD MOTOR CO.
35. Tighten bolts 10, 11, 13 and 14 in the sequence shown below to 3 Nm (27 lb-in).
    Fig 24: Identifying Oil Pan Mounting Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
36. Install the remaining oil pan bolts and tighten in the sequence shown below.
    • 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 25: Identifying Oil Pan Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
37. Install the Knock Sensor (KS) and the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 26: Locating Knock Sensor And Mounting Bolts

      Courtesy of FORD MOTOR CO.
38. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown below in 5 stages:
    • 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.
39. Install the RH M6 bolt.
    • Tighten to 10 Nm (89 lb-in).
40. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown below in 5 stages:
    • 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.
41. Install the LH M6 bolt.
    • Tighten to 10 Nm (89 lb-in).
42. Connect the Cylinder Head Temperature (CHT) sensor jumper harness.
    Fig 27: Locating CHT Sensor

    Courtesy of FORD MOTOR CO.
43. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Using new lower intake manifold gaskets, install the lower intake manifold and the 10 bolts and tighten in the sequence shown below.

    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Identifying Lower Intake Manifold Mounting Bolts Tightening Sequence

      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, RH similar.

    Install the valve tappets.

    Fig 29: Locating Valve Tappets

    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.

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 below.

    Fig 30: Identifying Camshafts On 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 below.

    Fig 31: 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 below.

    • Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
      Fig 32: Identifying Cylinder Head Mounting Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
49. Loosen the 4 camshaft caps bolts.
    Fig 33: Locating Camshaft Caps Mounting Bolts

    Courtesy of FORD MOTOR CO.
50. Tighten the 4 camshaft caps bolts in the sequence shown below.
    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
      Fig 34: Identifying Camshaft Caps Mounting 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 35: Measuring Valve Tappet Clearance Using Feeler Gauge

    Courtesy of FORD MOTOR CO.
52. Remove the 3 bolts and the RH valve train oil tube.
53. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown below.
54. 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.

55. 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 below.

    Fig 36: Identifying Camshafts On LH Cylinder Head In Neutral Position

    Courtesy of FORD MOTOR CO.
56. 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 below.

    Fig 37: Locating Camshaft Seals Gaps

    Courtesy of FORD MOTOR CO.
57. 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 below.

    • Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
      Fig 38: Identifying Cylinder Head Mounting Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
58. Loosen the 4 camshaft caps bolts.
    Fig 39: Locating Camshaft Caps Mounting Bolts

    Courtesy of FORD MOTOR CO.
59. Tighten the 4 camshaft caps bolts in the sequence shown below.
    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
      Fig 40: Identifying Camshaft Caps Mounting Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
60. 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 41: Measuring Valve Tappet Clearance Using Feeler Gauge

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

64. Using new gaskets, install the channel cover plate and the 9 bolts. Tighten in the sequence shown below in 2 stages:
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
65. Install the RH primary timing chain guide and the bolt.
    • 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.
66. 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.

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

71. 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.
72. 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.
73. 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.
74. 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.

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

79. 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.
80. 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.
81. 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 

82. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
83. Assemble the RH VCT  assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
    • Align the colored links with the timing marks.
84. 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.

85. 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.
86. NOTE: The 2 VCT  oil control solenoids are removed for clarity.

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

90. 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.
91. NOTE: The 2 VCT  oil control solenoids are removed for clarity.

    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 

92. Install the upper LH primary timing chain guide and the bolt.
    • Tighten to 10 Nm (89 lb-in).
93. Rotate the crankshaft clockwise 60 degrees to the Top Dead Center (TDC) position (crankshaft dowel pin at 11 o'clock).
94. Install the crankshaft timing chain sprocket with timing dot mark out.
95. 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 42: Aligning Primary Timing Chain Colored Links With Timing Marks On VCT Assemblies And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
96. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
97. Install the primary timing chain tensioner arm.
98. Reset the primary timing chain tensioner.
    • Release the ratchet detent.
    • Using a soft-jawed vise, compress the ratchet plunger.
    • Align the hole in the ratchet plunger with the hole in the tensioner housing.
    • Install a suitable lockpin.
99. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

    Install the primary tensioner and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.
100. 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).
101. 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.
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 RH intake VCT  oil control solenoid and the bolt.

     • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
103. Remove the RH Camshaft Holding Tool.
104. 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.
105. Remove the LH Camshaft Holding Tool.
106. 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.
107. NOTE: Use Spindle Bearing Installer 205-149 to install the seal.

     If removed, using the Spindle Bearing Installer, install the front cover radial seal from the rear side of the front cover.

108. 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 these instructions may 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.
109. 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 sequence shown below 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 43: Identifying Engine Front Cover Mounting Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
110. Install the remaining 12 engine front cover bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 16 and 22. Tighten all of the engine front cover bolts in the sequence shown below 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 44: Identifying Engine Front Cover Bolts Tightening Sequence

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

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

     If equipped, install the new oil cooler and the mounting bolt.

     • Tighten to 58 Nm (43 lb-ft).
113. Install the Crankshaft Position (CKP) sensor and install the bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 46: Locating CKP Sensor And Mounting Bolt

       Courtesy of FORD MOTOR CO.
114. Install the 2 RH Camshaft Position (CMP) sensors and the bolts.
     • Tighten to 10 Nm (89 lb-in).
115. Install the 2 LH CMP  sensors and the bolts.
     • Tighten to 10 Nm (89 lb-in).
116. Install 6 new RH exhaust manifold studs.
     • Tighten to 12 Nm (106 lb-in).
       Fig 47: Locating RH Exhaust Manifold Studs

       Courtesy of FORD MOTOR CO.
117. 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 6 new nuts. Tighten in 2 stages in the sequence shown below :

     • Stage 1: Tighten to 19 Nm (168 lb-in).
     • Stage 2: Tighten to 25 Nm (18 lb-ft).
       Fig 48: Identifying RH Exhaust Manifold Mounting Nuts Tightening Sequence

       Courtesy of FORD MOTOR CO.
118. Install the RH exhaust manifold heat shield and the 2 bolts.
     • Tighten to 10 Nm (89 lb-in).
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 3 bolts and 8 stud bolts in the sequence shown below.
     • Tighten to 10 Nm (89 lb-in).
       Fig 49: Identifying RH Valve Cover Mounting Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
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: 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).
125. 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 50: Locating Spark Plug

       Courtesy of FORD MOTOR CO.
126. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts.
     • Tighten to 7 Nm (62 lb-in).
127. Install 6 new LH exhaust manifold studs.
     • Tighten to 12 Nm (106 lb-in).
       Fig 51: Locating LH Exhaust Manifold Studs

       Courtesy of FORD MOTOR CO.
128. 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 6 new nuts. Tighten in 2 stages in the sequence shown below :

     • Stage 1: Tighten to 19 Nm (168 lb-in).
     • Stage 2: Tighten to 25 Nm (18 lb-ft).
       Fig 52: Identifying LH Exhaust Manifold Mounting Nuts Tightening Sequence

       Courtesy of FORD MOTOR CO.
129. Install the LH exhaust manifold heat shield and the 2 bolts.
     • Tighten to 10 Nm (89 lb-in).
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 4 bolts and 7 stud bolts in the sequence shown below.
     • Tighten to 10 Nm (89 lb-in).
       Fig 53: Identifying LH Valve Cover Mounting Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
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 54: Locating Spark Plug

       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).
138. 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 the sequence shown below in 2 stages:

     • Stage 1: Tighten to 10 Nm (89 lb-in).
     • Stage 2: Tighten an additional 45 degrees.
       Fig 55: Identifying Coolant Pump Mounting Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
139. Install the coolant pump pulley and the 4 bolts.
     • Tighten to 24 Nm (18 lb-ft).
140. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.

     Install the thermostat housing and the 4 bolts and tighten in the sequence shown below in 2 stages:

     • Stage 1: Tighten to 8 Nm (71 lb-in).
     • Stage 2: Tighten an additional 45 degrees.
       Fig 56: Identifying Thermostat Housing Mounting Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
141. Install the heater hose bracket on the valve cover stud bolt and install the nut.
     • Tighten to 8 Nm (71 lb-in).
142. Install the RH cylinder block drain plug.
     • Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
143. Install the LH cylinder block drain plug.
     • Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
144. Install the accessory drive belt tensioner and the 2 bolts.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 57: Locating Accessory Drive Belt Tensioner And Mounting Bolts

       Courtesy of FORD MOTOR CO.
145. 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 58: Installing Crankshaft Front Seal Using Suitable Tool

     Courtesy of FORD MOTOR CO.
146. Lubricate the crankshaft front seal inner lip with clean engine oil.
147. 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 59: Installing Crankshaft Pulley Using Suitable Tool

     Courtesy of FORD MOTOR CO.
148. 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 60: Installing Crankshaft Pulley Washer And Bolt Using Suitable Tool

       Courtesy of FORD MOTOR CO.
149. Attach all of the wiring harness retainers to the LH cylinder head, valve cover and stud bolts.
150. Connect the CRP  sensor electrical connector.
     Fig 61: Locating Crankshaft Position Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
151. Install the wiring harness grommet.
     Fig 62: Locating Wiring Harness Grommet

     Courtesy of FORD MOTOR CO.
152. Install the wiring harness retainer stud bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 63: Locating Wiring Harness Retainer Stud Bolt

       Courtesy of FORD MOTOR CO.
153. Install the heat shield, the nut and the bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 64: Locating Heat Shield With Mounting Bolt And Nut

       Courtesy of FORD MOTOR CO.
154. Connect the 2 LH CMP  sensors electrical connectors.
     • Attach the wiring harness retainer to the rear of the cylinder head.
155. Connect the KS electrical connector.
156. Connect the 2 LH VCT  solenoid electrical connectors.
157. Connect the 3 LH fuel rail electrical connectors.
158. Connect the 3 LH ignition coil-on-plug electrical connectors.
159. Connect the Engine Oil Pressure (EOP) switch electrical connector.
     • Attach the EOP  switch wiring harness retainer to the cylinder head.
160. Attach all of the wiring harness retainers to the RH cylinder head, valve cover and stud bolts.
161. Connect the 2 RH CMP  sensors electrical connectors.
162. Connect the 2 RH VCT  solenoid electrical connectors.
163. Connect the 3 RH fuel rail electrical connectors.
164. Connect the CHT sensor wiring harness jumper electrical connector.
165. Connect the 3 RH ignition coil-on-plug electrical connectors.
166. Install the RH fuel rail insulator.
167. Install the LH fuel rail insulator.
168. Install the engine oil level indicator.
169. Install the LH engine support insulator-to-cylinder block bracket and the 4 bolts.
     • Tighten to 63 Nm (46 lb-ft).
170. Install the RH engine support insulator and the 4 bolts.
     • Tighten to 63 Nm (46 lb-ft).
171. Install the A/C compressor and the 3 bolts.
     • Tighten to 25 Nm (18 lb-ft).
172. Install the LH and RH engine lift eyes.
     • Tighten to 25 Nm (18 lb-ft).
173. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
     Fig 65: Lifting Engine Using Heavy Duty Floor Crane And Spreader Bar

     Courtesy of FORD MOTOR CO.
174. Install the crankshaft sensor ring.
     Fig 66: Locating Crankshaft Sensor Ring

     Courtesy of FORD MOTOR CO.
175. Install the spacer plate.
     Fig 67: Locating Spacer Plate

     Courtesy of FORD MOTOR CO.
176. Install the flexplate and the 8 bolts and tighten is sequence shown below.
     • Tighten to 80 Nm (59 lb-ft).
       Fig 68: Identifying Flexplate Mounting Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.