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Section 675 (Engine - 2.7L ECOBOOST (238KW/324PS)): Assembly: Engine

WARNING: This page is about a different car, the 2015 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) / General Equipment 

GFD38522Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W) Handle
GFD39292Courtesy of FORD MOTOR COMPANY
 303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD39257Courtesy of FORD MOTOR COMPANY
 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD39287Courtesy of FORD MOTOR COMPANY
 303-1248 Camshaft holding tools TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD39099Courtesy of FORD MOTOR COMPANY
 303-1250 Seal Installer, Rear Main TKIT-2006UFFLM
GFD39087Courtesy of FORD MOTOR COMPANY
 303-1531 Installer, Front Crank Seal and Damper
GFD39459Courtesy of FORD MOTOR COMPANY
 303-1633 Remover, Roller Rocker Follower TKIT-2014D-FL_ROW TKIT-2014D-ROW3
GFD39293Courtesy of FORD MOTOR COMPANY
 303-1634 Lift Eyes (2) TKIT-2014D-FL_ROW TKIT-2014D-ROW3
GFD39088Courtesy of FORD MOTOR COMPANY
 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal TKIT-1988-F TKIT-1988-FLM
Floor Crane
Mounting Stand
Hose Clamp Remover/Installer
Flat-Bladed Screwdriver
Piston Ring Compressor
Vise
Vise Jaw Protectors

Materials 

Name Specification
Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP WSS-M2C946-A
Motorcraft ® High Performance Engine RTV Silicone TA-357 WSE-M4G323-A6
Flange Sealant CU7Z-19B508-A WSS-M2G348-A11
Motorcraft ® Orange Concentrated Antifreeze/Coolant VC-3-B WSS-M97B44-D
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.
NOTE: Refer to the exploded view under the Engine Component View  in the Description and Operation.

  1. 1.

    Read and record the four character code on the cylinder block face, they are arranged as follows: *##*##*. The first letter after the first asterisk is the code for main No. 1 and the next letter for main No, 2. The first letter after the second asterisk is the code for main No. 3 and the last letter for main No. 4.
GFD39460Courtesy of FORD MOTOR COMPANY

  1. 2.

    Read and record the four character code on the crankshaft face, they are arranged as follows: *##*##*. The first letter after the first asterisk is the code for main No. 1 and the next letter for main No, 2. The first letter after the second asterisk is the code for main No. 3 and the last letter for main No. 4.
GFD39461Courtesy of FORD MOTOR COMPANY

  1. 3.

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

    1. 1.

      Look at the bearing select fit chart and for each main, match the block and crankshaft code with its corresponding column or row by reading across the crankshaft row and down the block column to select the proper grade bearings for each main.

    1. 2.

      For example, if the block code is *BL*KH* and the crankshaft code is *SU*TQ*, main No. 1 should be assembled with grade 1 bearings, as determined by the intersection of the B  block column and the S  crankshaft row. Mains No. 2, 3 and 4 should all be grade 2.
GFD39462Courtesy of FORD MOTOR COMPANY

  1. 4.

    Install the piston cooling jets and bolts into the cylinder block.

    Torque

    : 89 lb.in (10 Nm)

GFD39412Courtesy of FORD MOTOR COMPANY

  1. 5.

    Install the crankshaft main bearings.
    • Install the crankshaft upper main bearings and thrust bearing into the cylinder block.
    • Install the crankshaft lower main bearings into the bearing caps.
    • Make sure all oil passages are aligned.
    • Lubricate all main bearings with clean engine oil.

      Material

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

GFD39463Courtesy of FORD MOTOR COMPANY

  1. 6.

    NOTE: Lubricate the crankshaft bearing journals with clean engine oil.

    Install the crankshaft into the cylinder block.

    Material

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

GFD39464Courtesy of FORD MOTOR COMPANY

  1. 7.

    Install the No. 1, 2 and 3 main bearing caps and bolts on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the cap bolts.

    Material

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

GFD39465Courtesy of FORD MOTOR COMPANY

  1. 8.

    NOTE: Lubricate the lower thrust washer with clean engine oil.

    Install the lower thrust washer and the No. 4 main bearing cap and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap bolts.

    Material

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

GFD39466Courtesy of FORD MOTOR COMPANY

  1. 9.

    Push the crankshaft forward to seat the crankshaft thrust washer.
GFD39467Courtesy of FORD MOTOR COMPANY

  1. 10.

    Tighten the main bearing cap bolts.

    Torque

    : Stage 1: 30 lb.ft (40 Nm) Stage 2: Loosen: 360 ° Stage 3: 26 lb.ft (35 Nm) Stage 4: 180 °

Fig 1: Main Bearing Cap Bolts Tightening Sequence
GFD39468Courtesy of FORD MOTOR CO.

  1. 11.

    • Check the piston-to-cylinder block and piston ring clearances. Refer to: Specifications .
    • Assemble the pistons and position the piston ring gaps. Refer to: Piston .

  1. 12.

    Lubricate with clean engine oil and install the connecting rod bearings.

    Material

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

GFD39469Courtesy of FORD MOTOR COMPANY

  1. 13.

    1. 1.

      For assembly purposes the bump on the connecting rod will face the same way as the bump on the connecting rod cap.
GFD39450Courtesy of FORD MOTOR COMPANY

  1. 14.

    1. 1.

      For assembly purposes the bowl on the dome of the piston should be facing toward the intake of the engine.

    1. 2.

      On the RH bank the bump on the connecting rod should face the front of the engine.

    1. 3.

      On the LH bank the bump on the connecting rod should face the rear of the engine.
GFD39451Courtesy of FORD MOTOR COMPANY

  1. 15.

    NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
    NOTE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.
    NOTE: Lubricate the piston with clean engine oil.
    • Position the piston assembly and piston ring installer into the cylinder. Use the General Equipment: Piston Ring Compressor

      Material

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

      NOTE: A commercially available piston rod installer must be used to prevent damage to the crankshaft journal.
    • Install a piston rod installer over the crankshaft journal and into the bolt holes of the connecting rod.
    • Push the piston into the cylinder bore and guide the connecting rod onto the crankshaft journal.
GFD39470Courtesy of FORD MOTOR COMPANY

  1. 16.

    NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

    1. 1.

      Install the connecting rod cap and bearing.

      Torque

      : Stage 1: 24 lb.ft (32 Nm) Stage 2: Loosen: 180 ° Stage 3: 24 lb.ft (32 Nm) Stage 4: 90 °

    1. 2.

      Repeat the steps for each of the remaining pistons.
GFD39471Courtesy of FORD MOTOR COMPANY

  1. 17.

    NOTE: If the engine block skirt stiffener is not installed, aligned and the bolts tightened to minimum specification within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply a 4.5 mm (0.18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine block skirt stiffener.

    Material

    : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD39472Courtesy of FORD MOTOR COMPANY

  1. 18.

    1. 1.

      Position the oil seal.

    1. 2.

      Install the engine block skirt stiffener.
GFD39473Courtesy of FORD MOTOR COMPANY

  1. 19.

    1. 1.

      Install the bolts finger tight.

    1. 2.

      Tighten the 2 bolts.

      Torque

      : Stage 1: 35 lb.in (4 Nm) Stage 2: Loosen: 360 °

GFD39474Courtesy of FORD MOTOR COMPANY

  1. 20.

    1. 1.

      Using a straight edge, align the rear face of the engine block skirt stiffener to the rear face of the engine block, flush or up to 0.250 mm (0.01 in) underflush.

    1. 2.

      Using a straight edge, align the machined bosses on the left side of the engine block skirt stiffener to the machined bosses on the left side of the engine block flush or within 0.280 mm (0.011 in) of flush.
GFD39475Courtesy of FORD MOTOR COMPANY

  1. 21.

    NOTE: If the engine block skirt stiffener bolts minimal torque is not completed within 10 minutes of sealant application, or if final torque is not met within 60 minutes of sealant application the parts must be removed and the sealant must be removed and the sealing area cleaned.

    Tighten the engine block skirt stiffener bolts.

    Torque

    : Stage 1: 35 lb.in (4 Nm) Stage 2: 18 lb.ft (24 Nm)

Fig 2: Engine Block Skirt Stiffener Bolts Tightening Sequence
GFD39476Courtesy of FORD MOTOR CO.

  1. 22.

    NOTE: Do not reuse the ECT sensor, install a new sensor.

    Install a new ECT sensor.

    Torque

    : 20 lb.ft (27 Nm)

GFD39477Courtesy of FORD MOTOR COMPANY

  1. 23.

    1. 1.

      Install the KS assembly and the bolts.

      Torque

      : 97 lb.in (11 Nm)

    1. 2.

      Connect the ECT sensor electrical connector.
GFD39478Courtesy of FORD MOTOR COMPANY

  1. 24.

    Inspect the coolant outlet connector pipe gasket and replace if damaged.
GFD39479Courtesy of FORD MOTOR COMPANY

  1. 25.

    1. 1.

      Install the coolant outlet connector pipe, the bolts and the stud bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Attach the wiring harness retainer to the stud bolt.
GFD39480Courtesy of FORD MOTOR COMPANY

  1. 26.

    Install the timing chain sprocket.
GFD39244Courtesy of FORD MOTOR COMPANY

  1. 27.

    NOTE: Rotate the crankshaft utilizing only the original crankshaft pulley bolt. Failure to follow this direction may cause damage to the crankshaft and result in engine failure.

    Install the original crankshaft pulley bolt and rotate the crankshaft clockwise until the keyway is at the 9 o'clock position.

GFD39481Courtesy of FORD MOTOR COMPANY

  1. 28.

    Install a new cylinder head gasket.
GFD39117Courtesy of FORD MOTOR COMPANY

  1. 29.

    • Install the cylinder head.
    • Install new cylinder head bolts.

      Torque

      : Stage 1: 177 lb.in (20 Nm) Stage 2: Loosen: 2 turn(s) Stage 3: 37 lb.ft (50 Nm) Stage 4: 180 °

Fig 3: LH Cylinder Head Bolts Tightening Sequence
GFD39118Courtesy of FORD MOTOR CO.

  1. 30.

    Inspect the O-ring and replace if damaged.
GFD39112Courtesy of FORD MOTOR COMPANY

  1. 31.

    1. 1.

      Install the cylinder head to coolant outlet connector hose assembly and the bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Connect the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer
GFD39111Courtesy of FORD MOTOR COMPANY

  1. 32.

    NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.
    NOTE: If the original hydraulic lash adjusters are to be reinstalled, they must be installed in their original locations.

    1. 1.

      Lubricate the hydraulic lash adjusters with clean engine oil.

      Material

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

    1. 2.

      Install the hydraulic lash adjusters.
GFD39482Courtesy of FORD MOTOR COMPANY

  1. 33.

    NOTE: Lubricate the camshafts with clean engine oil prior to installation.

    Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

    Material

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

GFD39076Courtesy of FORD MOTOR COMPANY

  1. 34.

    Apply a 1 mm bead of sealant to the rear camshaft cap mounting surface of the cylinder head.

    Material

    : Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

GFD39077Courtesy of FORD MOTOR COMPANY

  1. 35.

    Install the camshaft bearing caps and the bolts. Do not tighten at this time.
GFD39483Courtesy of FORD MOTOR COMPANY

  1. 36.

    Install the front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time.
GFD39484Courtesy of FORD MOTOR COMPANY

  1. 37.

    Tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 4: LH Camshaft Bolts Tightening Sequence
GFD39485Courtesy of FORD MOTOR CO.

  1. 38.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For installation of the LH side the circle marks are used.

    1. 1.

      Install the VCT units. The circle  timing marks on the VCT units will be at the 10 o'clock (intake) and 12:30 (exhaust) positions as shown in the illustration. Install Special Service Tool: 303-1248 Camshaft holding tools.

    1. 2.

      Install the new VCT unit bolts.

      Torque

      : Stage 1: 30 lb.ft (40 Nm) Stage 2: Loosen: 360 ° Stage 3: 37 lb.ft (50 Nm) Stage 4: 90 °

    1. 3.

      Remove Special Service Tool: 303-1248 Camshaft holding tools.
GFD39290Courtesy of FORD MOTOR COMPANY

  1. 39.

    Install a new cylinder head gasket.
GFD39125Courtesy of FORD MOTOR COMPANY

  1. 40.

    • Install the cylinder head.
    • Install new cylinder head bolts.

      Torque

      : Stage 1: 177 lb.in (20 Nm) Stage 2: Loosen: 2 turn(s) Stage 3: 37 lb.ft (50 Nm) Stage 4: 180 °

Fig 5: RH Cylinder Head Bolts Tightening Sequence
GFD39126Courtesy of FORD MOTOR CO.

  1. 41.

    Inspect the O-ring and replace if damaged.
GFD39112Courtesy of FORD MOTOR COMPANY

  1. 42.

    1. 1.

      Install the cylinder head to coolant outlet connector hose assembly and the bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Connect the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer
GFD39121Courtesy of FORD MOTOR COMPANY

  1. 43.

    NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.
    NOTE: If the original hydraulic lash adjusters are to be reinstalled, they must be installed in their original locations.

    1. 1.

      Lubricate the hydraulic lash adjusters with clean engine oil.

      Material

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

    1. 2.

      Install the hydraulic lash adjusters.
GFD39486Courtesy of FORD MOTOR COMPANY

  1. 44.

    NOTE: Lubricate the camshafts with clean engine oil prior to installation.

    Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

    Material

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

GFD39084Courtesy of FORD MOTOR COMPANY

  1. 45.

    Apply a 1 mm bead of sealant to the rear camshaft cap mounting surface of the cylinder head.

    Material

    : Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

GFD39085Courtesy of FORD MOTOR COMPANY

  1. 46.

    Install the camshaft bearing caps and the bolts. Do not tighten at this time.
GFD39487Courtesy of FORD MOTOR COMPANY

  1. 47.

    Install the front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time.
GFD39488Courtesy of FORD MOTOR COMPANY

  1. 48.

    Tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 6: RH Camshaft Bolts Tightening Sequence
GFD39489Courtesy of FORD MOTOR CO.

  1. 49.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For installation of the RH side the triangle marks are used.

    1. 1.

      Install the VCT units. The triangle  timing marks on the VCT units will be at the 2 o'clock (intake) and 11 o'clock (exhaust) positions as shown in the illustration. Install Special Service Tool: 303-1248 Camshaft holding tools.

    1. 2.

      Install the new VCT unit bolts.

      Torque

      : Stage 1: 30 lb.ft (40 Nm) Stage 2: Loosen: 360 ° Stage 3: 37 lb.ft (50 Nm) Stage 4: 90 °

    1. 3.

      Remove Special Service Tool: 303-1248 Camshaft holding tools.
GFD39291Courtesy of FORD MOTOR COMPANY

  1. 50.

    Install the oil pump and the bolts.

    Torque

    : Stage 1: 89 lb.in (10 Nm) Stage 2: 45 °

GFD39367Courtesy of FORD MOTOR COMPANY

  1. 51.

    Using the original crankshaft pulley bolt, rotate the crankshaft clockwise until the keyway is at the 11 o'clock position.
GFD39490Courtesy of FORD MOTOR COMPANY

  1. 52.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the LH side the circle marks are used.

    1. 1.

      Install the LH timing chain with the single colored links aligned with the circle  timing marks on the VCT units.

    1. 2.

      Install the double colored links so they straddle the timing mark on the crankshaft sprocket.
GFD39245Courtesy of FORD MOTOR COMPANY

  1. 53.

    Install the LH timing chain guide and bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39242Courtesy of FORD MOTOR COMPANY

  1. 54.

    Install the LH timing chain tensioner arm.
GFD39241Courtesy of FORD MOTOR COMPANY

  1. 55.

    Slide the tensioner cylinder out of the LH timing chain tensioner housing.
GFD39246Courtesy of FORD MOTOR COMPANY

  1. 56.

    NOTE: Use vise jaw protectors or cover the jaws of the vise with clean shop towels to prevent damage to the surface of the tensioner ratchet mechanism.

    Mount the flat machined surfaces on the end of the tensioner cylinder into a vise.

    1. 1.

      Using a flat-bladed screwdriver apply light downward pressure on the end of the tensioner ratchet mechanism. Use the General Equipment: Vise Use the General Equipment: Vise Jaw Protectors Use the General Equipment: Flat-Bladed Screwdriver

    1. 2.

      Rotate the screwdriver clockwise approximately one turn.

    1. 3.

      An audible click will be heard when the tensioner ratchet mechanism locks into place.
GFD39247Courtesy of FORD MOTOR COMPANY

  1. 57.

    1. 1.

      Slide the tensioner cylinder into the LH timing chain tensioner housing to the fully retracted position.

    1. 2.

      Install a retaining pin into the hole in the housing to lock the cylinder in the retracted position.
GFD39248Courtesy of FORD MOTOR COMPANY

  1. 58.

    1. 1.

      Position the LH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.

    1. 2.

      Install the bolts.

      Torque

      : 89 lb.in (10 Nm)

    1. 3.

      Remove the pin.
GFD39249Courtesy of FORD MOTOR COMPANY

  1. 59.

    Install the oil pump drive chain.
GFD39239Courtesy of FORD MOTOR COMPANY

  1. 60.

    Install oil pump drive chain guide and bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39238Courtesy of FORD MOTOR COMPANY

  1. 61.

    1. 1.

      Install the oil pump drive chain tensioner and bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Remove the pin.
GFD39250Courtesy of FORD MOTOR COMPANY

  1. 62.

    1. 1.

      Using the original crankshaft pulley bolt, rotate the crankshaft clockwise one revolution (360 degrees).

    1. 2.

      Position the crankshaft sprocket keyway at the 11 o'clock position.
GFD39251Courtesy of FORD MOTOR COMPANY

  1. 63.

    Remove and discard the original crankshaft pulley bolt.
GFD39491Courtesy of FORD MOTOR COMPANY

  1. 64.

    Install the timing chain sprocket.
GFD39233Courtesy of FORD MOTOR COMPANY

  1. 65.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the RH side the triangle marks are used.

    1. 1.

      Install the RH timing chain with the single colored links aligned with the triangle  timing marks on the VCT units.

    1. 2.

      Install the double colored links so they straddle the timing mark on the crankshaft sprocket.
GFD39253Courtesy of FORD MOTOR COMPANY

  1. 66.

    Install the RH timing chain guide and bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39230Courtesy of FORD MOTOR COMPANY

  1. 67.

    Install the RH timing chain tensioner arm.
GFD39229Courtesy of FORD MOTOR COMPANY

  1. 68.

    Slide the tensioner cylinder out of the RH timing chain tensioner housing.
GFD39254Courtesy of FORD MOTOR COMPANY

  1. 69.

    NOTE: Use vise jaw protectors or cover the jaws of the vise with clean shop towels to prevent damage to the surface of the tensioner ratchet mechanism.

    Mount the flat machined surfaces on the end of the tensioner cylinder into a vise.

    1. 1.

      Using a flat-bladed screwdriver apply light downward pressure on the end of the tensioner ratchet mechanism. Use the General Equipment: Vise Use the General Equipment: Vise Jaw Protectors Use the General Equipment: Flat-Bladed Screwdriver

    1. 2.

      Rotate the screwdriver clockwise approximately one turn.

    1. 3.

      An audible click will be heard when the tensioner ratchet mechanism locks into place.
GFD39247Courtesy of FORD MOTOR COMPANY

  1. 70.

    1. 1.

      Slide the tensioner cylinder into the RH timing chain tensioner housing to the fully retracted position.

    1. 2.

      Install a retaining pin into the hole in the housing to lock the cylinder in the retracted position.
GFD39255Courtesy of FORD MOTOR COMPANY

  1. 71.

    1. 1.

      Position the RH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.

    1. 2.

      Install the bolts.

      Torque

      : 89 lb.in (10 Nm)

    1. 3.

      Remove the pin.
GFD39256Courtesy of FORD MOTOR COMPANY

  1. 72.

    Install new engine front cover gaskets.
GFD39142Courtesy of FORD MOTOR COMPANY

  1. 73.

    Lubricate and install a new oil gallery seal (6G068).

    Material

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

GFD39143Courtesy of FORD MOTOR COMPANY

  1. 74.

    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 engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    Apply a 9 mm (0.35 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the cylinder block skirt-to-cylinder block joint and the cylinder head-to-cylinder block joint areas as indicated.

    Material

    : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD39144Courtesy of FORD MOTOR COMPANY

  1. 75.

    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 engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    Apply a 4.5 mm (0.18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.

    Material

    : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD39145Courtesy of FORD MOTOR COMPANY

  1. 76.

    Install the engine front cover and the fasteners.

    Torque

    : Stage 1: Tighten bolts 1 thru 11 to: 18 lb.ft (24 Nm) Stage 2: Tighten bolts 12 thru 13 to: 35 lb.ft (48 Nm) Stage 3: Tighten bolts 14 thru 21 to: 18 lb.ft (24 Nm)

Fig 7: Engine Front Cover Bolts Tightening Sequence
GFD39146Courtesy of FORD MOTOR CO.

  1. 77.

    Lubricate the engine front cover bore with clean engine oil.

    Material

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

GFD39093Courtesy of FORD MOTOR COMPANY

  1. 78.

    Using the special tools, install the new crankshaft front oil seal. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1531 Installer, Front Crank Seal and Damper.
GFD39094Courtesy of FORD MOTOR COMPANY

  1. 79.

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

    Material

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

GFD39095Courtesy of FORD MOTOR COMPANY

  1. 80.

    Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.

    Material

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

GFD39096Courtesy of FORD MOTOR COMPANY

  1. 81.

    Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1531 Installer, Front Crank Seal and Damper.
GFD39097Courtesy of FORD MOTOR COMPANY

  1. 82.

    NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).

    Using a universal pulley holder, install and tighten a new crankshaft pulley bolt.

    Torque

    : Stage 1: 166 lb.ft (225 Nm) Stage 2: Loosen: 360 ° Stage 3: 26 lb.ft (35 Nm) Stage 4: 270 °

GFD39098Courtesy of FORD MOTOR COMPANY

  1. 83.

    Rotate the crankshaft pulley bolt clockwise to position the camshaft lobe upward for the camshaft roller follower to be installed.
GFD39492Courtesy of FORD MOTOR COMPANY

  1. 84.

    1. 1.

      Install Special Service Tool: 303-1633 Remover, Roller Rocker Follower.

    1. 2.

      Turn the knob on the special tool clockwise to depress the valve and spring.
GFD39493Courtesy of FORD MOTOR COMPANY

  1. 85.

    1. 1.

      Lubricate the camshaft roller follower with clean engine oil.

      Material

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

    1. 2.

      Install the camshaft roller follower.

    1. 3.

      Turn the knob on the special tool counterclockwise to raise the valve and spring. Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower.
    • Repeat steps for the remaining camshaft roller followers.
GFD39494Courtesy of FORD MOTOR COMPANY

  1. 86.

    NOTE: Installation of new seals is only required if damaged seals were removed.

    Using the special tools, install new spark plug tube seals. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

GFD39267Courtesy of FORD MOTOR COMPANY

  1. 87.

    Install a new gasket.
GFD39268Courtesy of FORD MOTOR COMPANY

  1. 88.

    NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

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

    Material

    : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD39269Courtesy of FORD MOTOR COMPANY

  1. 89.

    Install the valve cover and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 8: LH Valve Cover Bolts Tightening Sequence
GFD39270Courtesy of FORD MOTOR CO.

  1. 90.

    Install the oil level indicator.
GFD39261Courtesy of FORD MOTOR COMPANY

  1. 91.

    NOTE: Installation of new seals is only required if damaged seals were removed.

    Using the special tools, install new spark plug tube seals. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

GFD39283Courtesy of FORD MOTOR COMPANY

  1. 92.

    Install a new gasket.
GFD39284Courtesy of FORD MOTOR COMPANY

  1. 93.

    NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

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

    Material

    : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD39285Courtesy of FORD MOTOR COMPANY

  1. 94.

    Install the valve cover and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 9: RH Valve Cover Bolts Tightening Sequence
GFD39286Courtesy of FORD MOTOR CO.

  1. 95.

    Install a new oil pump seal.
GFD39217Courtesy of FORD MOTOR COMPANY

  1. 96.

    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 must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    1. 1.

      Apply a 4.5 mm (0.18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the new oil pan.

      Material

      : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    1. 2.

      Apply a 9 mm (0.35 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-cylinder block joint areas on the new oil pan.

      Material

      : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    1. 3.

      Inspect the crankcase ventilation passages to make sure they are not blocked by any sealer applied.
GFD39218Courtesy of FORD MOTOR COMPANY

  1. 97.

    Install the new oil pan and the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 10: Oil Pan Bolts Tightening Sequence
GFD39219Courtesy of FORD MOTOR CO.

  1. 98.

    Install the TC mounting studs.

    Torque

    : 102 lb.in (11.5 Nm)

GFD39495Courtesy of FORD MOTOR COMPANY

  1. 99.

    Install the new TC gasket.
GFD39496Courtesy of FORD MOTOR COMPANY

  1. 100.

    Install a new TC coolant supply tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

    Material

    : Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

GFD39497Courtesy of FORD MOTOR COMPANY

  1. 101.

    NOTE: Install the TC coolant supply tube to the engine block while installing the TC.

    Install the TC and then loosely install the new TC bolt and nuts. Install the TC coolant supply tube to the engine block while installing the TC.

GFD39498Courtesy of FORD MOTOR COMPANY

  1. 102.

    Tighten the TC bolt.

    Torque

    : 44 lb.ft (60 Nm)

GFD39499Courtesy of FORD MOTOR COMPANY

  1. 103.

    1. 1.

      Tighten the TC nut.

      Torque

      : 44 lb.ft (60 Nm)

    1. 2.

      Tighten the TC nut.

      Torque

      : 27 lb.ft (37 Nm)

GFD39500Courtesy of FORD MOTOR COMPANY

  1. 104.

    Re-tighten the TC bolt.

    Torque

    : 44 lb.ft (60 Nm)

GFD39499Courtesy of FORD MOTOR COMPANY

  1. 105.

    1. 1.

      Re-tighten the TC nut.

      Torque

      : 44 lb.ft (60 Nm)

    1. 2.

      Re-tighten the TC nut.

      Torque

      : 27 lb.ft (37 Nm)

GFD39500Courtesy of FORD MOTOR COMPANY

  1. 106.

    Install and tighten the TC coolant supply tube bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39397Courtesy of FORD MOTOR COMPANY

  1. 107.

    Install the new TC oil return tube-to-engine block gasket.
GFD39501Courtesy of FORD MOTOR COMPANY

  1. 108.

    Install a new TC oil return tube O-ring seal and then lubricate with clean engine oil.

    Material

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

GFD39502Courtesy of FORD MOTOR COMPANY

  1. 109.

    Install the TC oil return tube, then install and tighten the TC oil return tube bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39365Courtesy of FORD MOTOR COMPANY

  1. 110.

    Install a new TC coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

    Material

    : Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

GFD39497Courtesy of FORD MOTOR COMPANY

  1. 111.

    Install the TC coolant return tube to the TC, then install and tighten the TC coolant return tube bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39396Courtesy of FORD MOTOR COMPANY

  1. 112.

    Install the new TC oil supply tube O-ring seals and the new TC oil supply tube oil filter. Lubricate the new TC oil supply tube O-ring seals with clean engine oil.

    Material

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

GFD39503Courtesy of FORD MOTOR COMPANY

  1. 113.

    Install the TC oil supply tube, then install and tighten the TC oil supply tube bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39395Courtesy of FORD MOTOR COMPANY

  1. 114.

    Install and then tighten the TC mounting stud.

    Torque

    : 102 lb.in (11.5 Nm)

GFD39504Courtesy of FORD MOTOR COMPANY

  1. 115.

    Install the new TC gasket.
GFD39505Courtesy of FORD MOTOR COMPANY

  1. 116.

    Install a new TC coolant supply tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

    Material

    : Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

GFD39506Courtesy of FORD MOTOR COMPANY

  1. 117.

    NOTE: Install the TC coolant supply tube to the engine block while installing the TC.

    Loosely install the new TC retainers. Install the TC coolant supply tube to the engine block while installing the TC.

GFD39507Courtesy of FORD MOTOR COMPANY

  1. 118.

    Install and tighten the TC coolant supply tube bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39390Courtesy of FORD MOTOR COMPANY

  1. 119.

    Install the new TC oil return tube-to-engine block gasket.
GFD39501Courtesy of FORD MOTOR COMPANY

  1. 120.

    Install a new TC oil return tube O-ring seal and then lubricate with clean engine oil.

    Material

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

GFD39502Courtesy of FORD MOTOR COMPANY

  1. 121.

    Install the TC oil return tube, then install and tighten the TC oil return tube bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39362Courtesy of FORD MOTOR COMPANY

  1. 122.

    Install the new TC oil supply tube O-ring seals and the new TC oil supply tube oil filter. Lubricate the new TC oil supply tube O-ring seals with clean engine oil.

    Material

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

GFD39503Courtesy of FORD MOTOR COMPANY

  1. 123.

    Install the TC oil supply tube, then loosely install the oil supply tube bolt.
GFD39388Courtesy of FORD MOTOR COMPANY

  1. 124.

    Connect the TC oil supply tube to the TC, then install and tighten the TC oil supply tube bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39387Courtesy of FORD MOTOR COMPANY

  1. 125.

    Tighten the TC oil supply tube bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39388Courtesy of FORD MOTOR COMPANY

  1. 126.

    Install and then tighten the TC mounting stud.

    Torque

    : 102 lb.in (11.5 Nm)

GFD39508Courtesy of FORD MOTOR COMPANY

  1. 127.

    Loosely install the upper left TC nut.
GFD39509Courtesy of FORD MOTOR COMPANY

  1. 128.

    Tighten the TC retainers in the following sequence.

    1. 1.

      Tighten the bolt.

      Torque

      : 44 lb.ft (60 Nm)

    1. 2.

      Tighten the nut.

      Torque

      : 44 lb.ft (60 Nm)

    1. 3.

      Tighten the nut.

      Torque

      : 27 lb.ft (37 Nm)

    1. 4.

      Re-tighten the bolt.

      Torque

      : 44 lb.ft (60 Nm)

    1. 5.

      Re-tighten the nut.

      Torque

      : 44 lb.ft (60 Nm)

    1. 6.

      Re-tighten the nut.

      Torque

      : 27 lb.ft (37 Nm)

GFD39510Courtesy of FORD MOTOR COMPANY

  1. 129.

    Install a new TC coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

    Material

    : Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

GFD39497Courtesy of FORD MOTOR COMPANY

  1. 130.

    Install and connect the TC coolant return tube and clamp, then install and tighten the TC coolant return tube bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39383Courtesy of FORD MOTOR COMPANY

  1. 131.

    • Lubricate the inside and the outside diameter of the grommet with clean engine coolant.

      Material

      : Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

    • Install the grommet so it is flush with the rear of the coolant pump housing.
GFD39511Courtesy of FORD MOTOR COMPANY

  1. 132.

    NOTE: Verify the front cover dowel pins are aligned to the coolant pump and that the coolant pump is fully seated prior to installing the fasteners.
    • Using a new gasket, install the coolant pump and the fasteners.

      Torque

      : Fasteners 1-7: Stage 1: 89 lb.in (10 Nm) Stage 2: 45 °

    • Torque

      : Fastener 8: 18 lb.ft (24 Nm)

Fig 11: Coolant Pump Bolts Tightening Sequence
GFD39512Courtesy of FORD MOTOR CO.

  1. 133.

    Inspect the gaskets and replace if damaged.
GFD38921Courtesy of FORD MOTOR COMPANY

  1. 134.

    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.

    Apply 8 mm (0.14 in) beads of Motorcraft ® High Performance Engine RTV Silicone as shown below.

GFD38922Courtesy of FORD MOTOR COMPANY

  1. 135.

    Install the brake vacuum pump and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39381Courtesy of FORD MOTOR COMPANY

  1. 136.

    Install a new fuel rail-to-fuel rail high-pressure fuel tube and finger tighten the flare nuts.
    • Final tighten the flare nuts.

      Torque

      : Stage 1: 62 lb.in (7 Nm) Stage 2: 89 lb.in (10 Nm) Stage 3: 25 °

GFD39119Courtesy of FORD MOTOR COMPANY

  1. 137.

    Inspect the high-pressure fuel pump drive unit gasket and replace if damaged.
GFD39513Courtesy of FORD MOTOR COMPANY

  1. 138.

    Apply 8 mm dots of sealant to the camshaft bearing cap and cylinder head seam as shown below.

    Material

    : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD39514Courtesy of FORD MOTOR COMPANY

  1. 139.

    Install the high-pressure fuel pump drive unit and stud bolts.

    Torque

    : Stage 1: 177 lb.in (20 Nm) Stage 2: 45 °

GFD39515Courtesy of FORD MOTOR COMPANY

  1. 140.

    NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.
    NOTE: The drive lobe for the high-pressure fuel pump must be at BDC (bottom dead center) for the high-pressure fuel pump installation.

    Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC.

GFD39516Courtesy of FORD MOTOR COMPANY

  1. 141.

    NOTE: Align the notch on the high-pressure fuel pump tappet and with the groove in the high-pressure fuel pump drive unit bore.

    Apply clean engine oil to the high-pressure fuel pump drive unit bore, the drive lobe and the roller tappet. Install the high-pressure fuel pump tappet.

    Material

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

GFD39517Courtesy of FORD MOTOR COMPANY

  1. 142.

    NOTE: Apply clean engine oil to the high-pressure fuel pump O-ring seals.

    Install a new high-pressure fuel pump O-ring seal and lubricate with clean engine oil.

    Material

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

GFD39518Courtesy of FORD MOTOR COMPANY

  1. 143.

    Install the high-pressure fuel pump, then install and finger tighten the high-pressure fuel pump nuts. Alternately tighten each of the high-pressure fuel pump nuts one complete revolution until seated. Then tighten the fuel high-pressure fuel pump nuts in the following 2 stages.

    Torque

    : Stage 1: 177 lb.in (20 Nm) Stage 2: 45 °

GFD39375Courtesy of FORD MOTOR COMPANY

  1. 144.

    NOTE: Make sure that a new high-pressure fuel pump-to-fuel rail high-pressure fuel tube is installed.

    Install the high-pressure fuel pump-to-fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

    Torque

    : Stage 1: 62 lb.in (7 Nm) Stage 2: 89 lb.in (10 Nm) Stage 3: 25 °

GFD39519Courtesy of FORD MOTOR COMPANY

  1. 145.

    Install the gaskets.
GFD39194Courtesy of FORD MOTOR COMPANY

  1. 146.

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

    Install the intake manifold and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 12: Intake Manifold Bolts Tightening Sequence
GFD39520Courtesy of FORD MOTOR CO.

  1. 147.

    Install the coolant pipe and the bolts.

    Torque

    : 97 lb.in (11 Nm)

GFD39191Courtesy of FORD MOTOR COMPANY

  1. 148.

    Inspect and replace any ignition coil-on-plugs that have rubber boots with cracks, rips or tears.
GFD39521Courtesy of FORD MOTOR COMPANY

  1. 149.

    1. 1.

      Install the ignition coil-on-plugs.

    1. 2.

      Install and tighten the ignition coil-on-plug stud bolts.

      Torque

      : 53 lb.in (6 Nm)

GFD39359Courtesy of FORD MOTOR COMPANY

  1. 150.

    Install the EVAP purge valve and connect the quick release coupling. Refer to: QUICK RELEASE COUPLING .
GFD39372Courtesy of FORD MOTOR COMPANY

  1. 151.

    1. 1.

      Install the vacuum tube assembly onto the engine and attach the retainers.

    1. 2.

      Install the vacuum control solenoid bolts.

      Torque

      : 62 lb.in (7 Nm)

    1. 3.

      Connect the vacuum tube quick release coupling. Refer to: QUICK RELEASE COUPLING .

    1. 4.

      Connect the vacuum hose and clamp to the TC.
GFD39358Courtesy of FORD MOTOR COMPANY

  1. 152.

    Connect the vacuum hose and clamp to the TC.
    • Attach the vacuum hose retainers.
GFD39357Courtesy of FORD MOTOR COMPANY

  1. 153.

    Install the engine wiring harness onto the engine.
    • Connect the engine wiring harness electrical connectors and attach the retainers.
GFD39356Courtesy of FORD MOTOR COMPANY

  1. 154.

    Connect the engine wiring harness electrical connectors and attach the retainers.
GFD39355Courtesy of FORD MOTOR COMPANY

  1. 155.

    Connect the engine wiring harness electrical connectors and attach the retainers.
GFD39186Courtesy of FORD MOTOR COMPANY

  1. 156.

    Connect the engine wiring harness electrical connectors and attach the retainers.
GFD39354Courtesy of FORD MOTOR COMPANY

  1. 157.

    Connect the oil control solenoid electrical connector and attach the wiring harness retainers.
GFD39353Courtesy of FORD MOTOR COMPANY

  1. 158.

    • Attach the wiring harness retainers.
    • Connect the fuel pump electrical connector.
    • Install the wiring harness ground terminal to the rear of the RH cylinder head and install the stud bolt.

      Torque

      : 89 lb.in (10 Nm)

GFD39352Courtesy of FORD MOTOR COMPANY

  1. 159.

    Install the ground terminal to the rear of the RH cylinder head stud bolt and install the nut.

    Torque

    : 89 lb.in (10 Nm)

GFD39351Courtesy of FORD MOTOR COMPANY

  1. 160.

    • Install the wiring harness ground terminal to the rear of the LH cylinder head and install the stud bolt.

      Torque

      : 89 lb.in (10 Nm)

    • Connect the KS wiring harness connector and attach the retainer.
GFD39350Courtesy of FORD MOTOR COMPANY

  1. 161.

    Install the engine appearance cover bracket and the bolts.

    Torque

    : 97 lb.in (11 Nm)

GFD39184Courtesy of FORD MOTOR COMPANY

  1. 162.

    Install a new oil cooler gasket.
GFD39522Courtesy of FORD MOTOR COMPANY

  1. 163.

    Install the oil cooler and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39348Courtesy of FORD MOTOR COMPANY

  1. 164.

    1. 1.

      Position the bracket with heater hose and install the nuts.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Connect the heater hose and clamp.
GFD39347Courtesy of FORD MOTOR COMPANY

  1. 165.

    Install the bracket and the nuts.

    Torque

    : 89 lb.in (10 Nm)

GFD39262Courtesy of FORD MOTOR COMPANY

  1. 166.

    Install the A/C compressor and the bolts.

    Torque

    : 18 lb.ft (25 Nm)

GFD39346Courtesy of FORD MOTOR COMPANY

  1. 167.

    Install the accessory drive belt tensioner, the idler pulley and the bolts.

    Torque

    : Tensioner: 18 lb.ft (25 Nm) Idler pulley: 18 lb.ft (24 Nm)

GFD39345Courtesy of FORD MOTOR COMPANY

  1. 168.

      NOTE: Do not tighten coolant pump pulley bolts at this time.
    • Install the coolant pump pulley bolts.
    • Install the idler pulley and the bolt.

      Torque

      : 35 lb.ft (48 Nm)

    • Install the generator, the bolt and the nut.

      Torque

      : 35 lb.ft (48 Nm)

GFD39344Courtesy of FORD MOTOR COMPANY

  1. 169.

    Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
GFD39523Courtesy of FORD MOTOR COMPANY

  1. 170.

    Make sure the accessory drive belt is correctly seated on all pulleys.
GFD39524Courtesy of FORD MOTOR COMPANY

  1. 171.

    Tighten the coolant pump pulley bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39342Courtesy of FORD MOTOR COMPANY

  1. 172.

    Install the auxiliary coolant pump and the bolts.

    Torque

    : 62 lb.in (7 Nm)

GFD39341Courtesy of FORD MOTOR COMPANY

  1. 173.

    • Connect the auxiliary coolant pump electrical connector.
    • Connect the coolant hoses and clamps.
GFD39340Courtesy of FORD MOTOR COMPANY

  1. 174.

    Install the engine mount and the new bolts.

    Torque

    : 57 lb.ft (77 Nm)

GFD39178Courtesy of FORD MOTOR COMPANY

  1. 175.

    Install the engine mount-to-cylinder block bracket and the new bolts.

    Torque

    : 57 lb.ft (77 Nm)

GFD39166Courtesy of FORD MOTOR COMPANY

  1. 176.

    Using a floor crane, remove the engine from the mounting stand. Install Special Service Tool: 303-1634 Lift Eyes (2)., 303-1246 Engine Spreader Bar. Use the General Equipment: Floor Crane Use the General Equipment: Mounting Stand
GFD39338Courtesy of FORD MOTOR COMPANY

  1. 177.

    Lubricate the crankshaft rear seal lips with clean engine oil.

    Material

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

GFD39105Courtesy of FORD MOTOR COMPANY

  1. 178.

    NOTE: The crankshaft rear seal and retainer plate must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    Apply a 4.5 mm (0.18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the crankshaft rear seal and retainer plate.

    Material

    : Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD39106Courtesy of FORD MOTOR COMPANY

  1. 179.

    • Position the special tool onto the end of the crankshaft. Use Special Service Tool: 303-1250 Seal Installer, Rear Main.
    • Slide the new crankshaft rear seal and retainer plate onto the tool and into the installed position.
GFD39107Courtesy of FORD MOTOR COMPANY

  1. 180.

    Install the crankshaft rear seal retainer plate bolts. Remove Special Service Tool: 303-1250 Seal Installer, Rear Main.

    Torque

    : 89 lb.in (10 Nm)

Fig 13: Crankshaft Rear Seal Retainer Plate Bolts Tightening Sequence
GFD39108Courtesy of FORD MOTOR CO.

  1. 181.

    1. 1.

      Install the CKP sensor and the bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Connect the CKP sensor electrical connector.

    1. 3.

      Position the CKP sensor electrical connector insulator.
GFD39109Courtesy of FORD MOTOR COMPANY

  1. 182.

    Install the crankshaft sensor ring and the engine-to-transmission spacer plate.
GFD39337Courtesy of FORD MOTOR COMPANY

  1. 183.

    1. 1.

      Position the flexplate on the crankshaft.

    1. 2.

      Install the bolts then rundown the bolts one turn at a time in sequence shown until the flexplate is snug against the rear face of the crankshaft.

    1. 3.

      Final tighten the bolts in sequence shown.

      Torque

      : 59 lb.ft (80 Nm)

Fig 14: Flexplate Bolts Tightening Sequence
GFD39525Courtesy of FORD MOTOR CO.
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