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Section 676 (Engine - 3.5L DURATEC (209KW/284PS)): 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 

GFD38404Courtesy of FORD MOTOR COMPANY
 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
GFD39783Courtesy of FORD MOTOR COMPANY
 205-142 (T80T-4000-J) Installer, Differential Bearing Cone
GFD39638Courtesy of FORD MOTOR COMPANY
 205-149 (T80T-4000-R) Installer, Spindle Bearing
GFD38522Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W) Handle
GFD39577Courtesy of FORD MOTOR COMPANY
 303-102 Installer, Crankshaft Pulley
GFD39660Courtesy of FORD MOTOR COMPANY
 303-1245 Engine Lift Eye 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
GFD39578Courtesy of FORD MOTOR COMPANY
 303-1251 Installer, Front Seal TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD39552Courtesy of FORD MOTOR COMPANY
 303-1530 Tool, Chain Tensioner Hold Down TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
GFD39088Courtesy of FORD MOTOR COMPANY
 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal TKIT-1988-F TKIT-1988-FLM
GFD39640Courtesy of FORD MOTOR COMPANY
 307-399 Alignment Pins, Transmission Fluid Pump TKIT-2000AP-FLM/LM TKIT-2002N-DEW
Feeler Gauge
Strap Wrench
Floor Crane
Mounting Stand
Hose Clamp Remover/Installer
Round-Ended Steel Rule
Piston Ring Compressor

Materials 

Name Specification
Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C945-A
Motorcraft ® High Performance Engine RTV Silicone TA-357 WSE-M4G323-A6
Motorcraft ® Silicone Gasket Remover ZC-30-A -
Motorcraft ® Metal Surface Prep ZC-31-B -
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, may cause engine failure.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components. These inspections/measurements will aid in determining if the engine components will require replacement. Refer to ENGINE SYSTEM - GENERAL INFORMATION .
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.

  1. 1.

    Using a hex bit, install the piston oil cool valves.

    Torque

    : 35 lb.in (4 Nm)

GFD39954Courtesy of FORD MOTOR COMPANY

  1. 2.

    NOTE: This step is for selecting the correct main bearings.
    NOTE: The #1 main bearing is at the front of the engine block.
    • Select the crankshaft main bearings for each crankshaft journal.
    • Record the code that is on the cylinder block face.
    • Record the code that is on the crankshaft flange.
    • The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.
GFD39984Courtesy of FORD MOTOR COMPANY

  1. 3.

    NOTE: This chart is continued in the next step.
    NOTE: This chart is for selecting main bearings 1 and 4 only.
    • 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.
GFD39985Courtesy of FORD MOTOR COMPANY

  1. 4.

    NOTE: This chart is for selecting main bearings 1 and 4 only.
GFD39986Courtesy of FORD MOTOR COMPANY

  1. 5.

    NOTE: This chart is continued in the next step.
    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.
GFD39987Courtesy of FORD MOTOR COMPANY

  1. 6.

    NOTE: This chart is for selecting main bearings 2 and 3 only.
GFD39988Courtesy of FORD MOTOR COMPANY

  1. 7.

    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.

    Torque

    : Stage 1: 17 lb.ft (23 Nm) Stage 2: 32 lb.ft (43 Nm) Stage 3: 90 °

GFD39989Courtesy of FORD MOTOR COMPANY

  1. 8.

    Measure the connecting rod large end bore in 2 directions.
GFD39990Courtesy of FORD MOTOR COMPANY

  1. 9.

    • Remove the bolts and the rod cap.
    • Discard the bolts.
GFD39991Courtesy of FORD MOTOR COMPANY

  1. 10.

    Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
GFD39992Courtesy of FORD MOTOR COMPANY

  1. 11.

    Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
GFD39993Courtesy of FORD MOTOR COMPANY

  1. 12.

    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 in the cylinder block.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD39994Courtesy of FORD MOTOR COMPANY

  1. 13.

    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.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD39951Courtesy of FORD MOTOR COMPANY

  1. 14.

    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.

GFD39995Courtesy of FORD MOTOR COMPANY

  1. 15.

    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.

GFD39996Courtesy of FORD MOTOR COMPANY

  1. 16.

    Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Check seating and squareness of the bearings to make sure of proper seating in caps.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD39997Courtesy of FORD MOTOR COMPANY

  1. 17.

    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.
GFD39998Courtesy of FORD MOTOR COMPANY

  1. 18.

    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.

GFD39949Courtesy of FORD MOTOR COMPANY

  1. 19.

    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.
GFD39999Courtesy of FORD MOTOR COMPANY

  1. 20.

    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.

    Torque

    : Stage 1: 24 lb.ft (33 Nm) Stage 2: 135 °

Fig 1: Main Bearing Bolts Tightening Sequence
GFD40000Courtesy of FORD MOTOR CO.

  1. 21.

    Install the new main bearing cap side bolts.

    Torque

    : Stage 1: 33 lb.ft (45 Nm) Stage 2: 90 °

Fig 2: Main Bearing Cap Side Bolts Tightening Sequence
GFD40001Courtesy of FORD MOTOR CO.

  1. 22.

    1. 1.

      Position the crankshaft to the rear of the cylinder block. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    1. 2.

      Zero the Dial Indicator Gauge.

    1. 3.

      Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play.
GFD40002Courtesy of FORD MOTOR COMPANY

  1. 23.

    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.
GFD40003Courtesy of FORD MOTOR COMPANY

  1. 24.

    NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring face pointing up toward the top of the piston.
    NOTE: The arrow on the top of the piston indicates the front of the engine.

    1. 1.

      Center line of the piston parallel to the wrist pin bore.

    1. 2.

      Upper compression ring gap location.

    1. 3.

      Upper oil control segment ring gap location.

    1. 4.

      Lower oil control segment ring gap location.

    1. 5.

      Expander ring and lower compression ring gap location.
GFD39983Courtesy of FORD MOTOR COMPANY

  1. 25.

    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: 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. Refer to Piston .
    NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.
    NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.

    Using the Piston Ring Compressor, install the piston and connecting rod assemblies. Repeat until all 6 piston assemblies are installed. Use the General Equipment: Piston Ring Compressor

GFD40004Courtesy of FORD MOTOR COMPANY

  1. 26.

    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 the new bolts.

    Torque

    : Stage 1: 17 lb.ft (23 Nm) Stage 2: 32 lb.ft (43 Nm) Stage 3: 90 °

GFD39945Courtesy of FORD MOTOR COMPANY

  1. 27.

    Install the main bearing cap support brace and the new bolts.

    Torque

    : Stage 1: 18 lb.ft (24 Nm) Stage 2: 180 °

Fig 3: Main Bearing Cap Support Brace Bolts Tightening Sequence
GFD40005Courtesy of FORD MOTOR CO.

  1. 28.

    NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.

    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.

GFD40006Courtesy of FORD MOTOR COMPANY

  1. 29.

    Lubricate the crankshaft rear seal with clean engine oil.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD39595Courtesy of FORD MOTOR COMPANY

  1. 30.

    Install the crankshaft rear seal and the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 4: Crankshaft Rear Seal Retaining Plate Bolts Tightening Sequence
GFD40007Courtesy of FORD MOTOR CO.

  1. 31.

    Install the oil pump and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39940Courtesy of FORD MOTOR COMPANY

  1. 32.

    Install a new oil pump screen and pickup tube O-ring seal.
GFD39761Courtesy of FORD MOTOR COMPANY

  1. 33.

    Install the oil pump screen and pickup tube and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39939Courtesy of FORD MOTOR COMPANY

  1. 34.

    NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    Apply a 3 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the oil pan.

GFD39762Courtesy of FORD MOTOR COMPANY

  1. 35.

    NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    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.

GFD39763Courtesy of FORD MOTOR COMPANY

  1. 36.

    Install the oil pan and bolts.

    Torque

    : Stage 1: 27 lb.in (3 Nm) Stage 2: Loosen:: 180 °

GFD40008Courtesy of FORD MOTOR COMPANY

  1. 37.

    Using a straight edge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown. Use the General Equipment: Round-Ended Steel Rule
GFD40009Courtesy of FORD MOTOR COMPANY

  1. 38.

    Tighten the bolts in the sequence,

    Torque

    : 27 lb.in (3 Nm)

Fig 5: Oil Pan Bolts Tightening Sequence
GFD40010Courtesy of FORD MOTOR CO.

  1. 39.

    Install the remaining oil pan bolts.

    Torque

    : Stage 1: Tighten bolts 1 through 14 to: 18 lb.ft (24 Nm) Stage 2: Tighten bolt 10 an additional: 90 ° Stage 3: Tighten bolts 15 and 16 to: 89 lb.in (10 Nm)

Fig 6: Oil Pan Bolts Tightening Sequence
GFD40011Courtesy of FORD MOTOR CO.
GFD40011Courtesy of FORD MOTOR COMPANY

  1. 40.

    Install the channel cover plate and the bolts.

    Torque

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

Fig 7: Channel Cover Plate Bolts Tightening Sequence
GFD40012Courtesy of FORD MOTOR CO.

  1. 41.

    Install the KS and the bolts.

    Torque

    : 177 lb.in (20 Nm)

GFD39932Courtesy of FORD MOTOR COMPANY

  1. 42.

    Install the LH cylinder head gasket.
GFD39611Courtesy of FORD MOTOR COMPANY

  1. 43.

    NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

    Install the cylinder head and the new bolts.

    Torque

    : Stage 1: 177 lb.in (20 Nm) Stage 2: 26 lb.ft (35 Nm) Stage 3: 90 ° Stage 4: 90 ° Stage 5: 45 °

Fig 8: LH Cylinder Head Bolts Tightening Sequence
GFD40013Courtesy of FORD MOTOR CO.

  1. 44.

    Install the M6 bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39613Courtesy of FORD MOTOR COMPANY

  1. 45.

    Install the RH cylinder head gasket.
GFD39631Courtesy of FORD MOTOR COMPANY

  1. 46.

    NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

    Install the cylinder head and the new bolts.

    Torque

    : Stage 1: 177 lb.in (20 Nm) Stage 2: 26 lb.ft (35 Nm) Stage 3: 90 ° Stage 4: 90 ° Stage 5: 45 °

Fig 9: RH Cylinder Head Bolts Tightening Sequence
GFD40014Courtesy of FORD MOTOR CO.

  1. 47.

    Install the M6 bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39633Courtesy of FORD MOTOR COMPANY

  1. 48.

    NOTE: Coat the valve tappets with clean engine oil prior to installation.
    NOTE: The valve tappets must be installed in their original positions.
    NOTE: RH shown, LH similar.

    Install the valve tappets.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD40015Courtesy of FORD MOTOR COMPANY

  1. 49.

    Install the RH primary timing chain guide and the bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39623Courtesy of FORD MOTOR COMPANY

  1. 50.

    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.

GFD40016Courtesy of FORD MOTOR COMPANY

  1. 51.

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

    Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral position as shown.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD40017Courtesy of FORD MOTOR COMPANY

  1. 52.

    NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the RH camshaft seals gaps as shown.

GFD39561Courtesy of FORD MOTOR COMPANY

  1. 53.

    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the camshaft caps, oil tube and the bolts.

    Torque

    : Stage 1: 71 lb.in (8 Nm) Stage 2: 45 °

Fig 10: RH Camshaft Bolts Tightening Sequence
GFD867Courtesy of FORD MOTOR CO.
GFD40018Courtesy of FORD MOTOR COMPANY

  1. 54.

    Loosen the camshaft cap bolts.
GFD40019Courtesy of FORD MOTOR COMPANY

  1. 55.

    Tighten the camshaft cap bolts.

    Torque

    : Stage 1: 71 lb.in (8 Nm) Stage 2: 45 °

GFD40020Courtesy of FORD MOTOR COMPANY

  1. 56.

    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.

    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. Refer to: Valve Clearance Adjustment . Use the General Equipment: Feeler Gauge

GFD39565Courtesy of FORD MOTOR COMPANY

  1. 57.

    Remove the bolts and the oil tube.
GFD39920Courtesy of FORD MOTOR COMPANY

  1. 58.

    Rotate the RH camshafts to TDC.
GFD40021Courtesy of FORD MOTOR COMPANY

  1. 59.

    NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1248 Camshaft holding tools.

GFD39557Courtesy of FORD MOTOR COMPANY

  1. 60.

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

    Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

GFD39556Courtesy of FORD MOTOR COMPANY

  1. 61.

    Align the colored links with the timing marks and assemble the RH VCT units.
GFD39830Courtesy of FORD MOTOR COMPANY

  1. 62.

    NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

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

GFD39821Courtesy of FORD MOTOR COMPANY

  1. 63.

    Install the new RH VCT unit bolts.

    Torque

    : Stage 1: 30 lb.ft (40 Nm) Stage 2: Loosen:: 1 turn(s) Stage 3: 18 lb.ft (25 Nm) Stage 4: 180 °

GFD39835Courtesy of FORD MOTOR COMPANY

  1. 64.

    NOTE: Make sure the secondary timing chain is centered on the timing chain tensioner guides.
    NOTE: The VCT oil control solenoids are removed for clarity.

    Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

GFD39819Courtesy of FORD MOTOR COMPANY

  1. 65.

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

    Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral position as shown.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD40022Courtesy of FORD MOTOR COMPANY

  1. 66.

    NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the LH camshaft seals gaps as shown.

GFD39569Courtesy of FORD MOTOR COMPANY

  1. 67.

    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the camshaft caps, oil tube and the bolts.

    Torque

    : Stage 1: 71 lb.in (8 Nm) Stage 2: 45 °

Fig 11: LH Camshaft Bolts Tightening Sequence
GFD40023Courtesy of FORD MOTOR CO.

  1. 68.

    Loosen the camshaft cap bolts.
GFD40024Courtesy of FORD MOTOR COMPANY

  1. 69.

    Tighten the camshaft cap bolts.

    Torque

    : Stage 1: 71 lb.in (8 Nm) Stage 2: 45 °

GFD40025Courtesy of FORD MOTOR COMPANY

  1. 70.

    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.

    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. Refer to: Valve Clearance Adjustment . Use the General Equipment: Feeler Gauge

GFD39573Courtesy of FORD MOTOR COMPANY

  1. 71.

    Remove bolts and the oil tube.
GFD39919Courtesy of FORD MOTOR COMPANY

  1. 72.

    Rotate the LH camshafts to TDC.
GFD40026Courtesy of FORD MOTOR COMPANY

  1. 73.

    NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1248 Camshaft holding tools.

GFD39554Courtesy of FORD MOTOR COMPANY

  1. 74.

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

    Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

GFD39553Courtesy of FORD MOTOR COMPANY

  1. 75.

    Align the colored links with the timing marks and assemble the LH VCT units.
GFD39840Courtesy of FORD MOTOR COMPANY

  1. 76.

    NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

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

GFD39814Courtesy of FORD MOTOR COMPANY

  1. 77.

    Install the new LH VCT unit bolts.

    Torque

    : Stage 1: 30 lb.ft (40 Nm) Stage 2: Loosen:: 1 turn(s) Stage 3: 18 lb.ft (25 Nm) Stage 4: 180 °

GFD39845Courtesy of FORD MOTOR COMPANY

  1. 78.

    NOTE: Make sure the secondary timing chain is centered on the timing chain tensioner guides.
    NOTE: The VCT oil control solenoids are removed for clarity.

    Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

GFD39812Courtesy of FORD MOTOR COMPANY

  1. 79.

    Install the LH upper primary timing chain guide and the bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39923Courtesy of FORD MOTOR COMPANY

  1. 80.

    Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
GFD40027Courtesy of FORD MOTOR COMPANY

  1. 81.

    Install the crankshaft sprocket.
GFD39768Courtesy of FORD MOTOR COMPANY

  1. 82.

    NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.

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

GFD39769Courtesy of FORD MOTOR COMPANY

  1. 83.

    Install the lower LH timing chain guide and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39751Courtesy of FORD MOTOR COMPANY

  1. 84.

    Install the timing chain tensioner arm.
GFD39750Courtesy of FORD MOTOR COMPANY

  1. 85.

    • 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 lockpin.
GFD39770Courtesy of FORD MOTOR COMPANY

  1. 86.

    NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.
    • Install the timing chain tensioner and the bolts.

      Torque

      : 89 lb.in (10 Nm)

    • Remove the lockpin.
GFD39771Courtesy of FORD MOTOR COMPANY

  1. 87.

    • As a post-check, verify correct alignment of all timing marks.
    • There are 48 links in between the RH intake VCT unit colored link (1) and the LH intake VCT unit colored link (2).
    • There are 35 links in between LH intake VCT unit colored link (2) and the 2 crankshaft sprocket links (3).
GFD39772Courtesy of FORD MOTOR COMPANY

  1. 88.

    NOTE: Do not use excessive force when installing the 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.

    Install the VCT oil control solenoids and the bolts.

    Torque

    : Stage 1: 71 lb.in (8 Nm) Stage 2: 20 °

GFD39921Courtesy of FORD MOTOR COMPANY

  1. 89.

    Remove Special Service Tool: 303-1248 Camshaft holding tools.
GFD39745Courtesy of FORD MOTOR COMPANY

  1. 90.

    Install the RH oil tube and the bolts.

    Torque

    : Stage 1: 71 lb.in (8 Nm) Stage 2: 45 °

GFD39920Courtesy of FORD MOTOR COMPANY

  1. 91.

    Remove Special Service Tool: 303-1248 Camshaft holding tools.
GFD39744Courtesy of FORD MOTOR COMPANY

  1. 92.

    Install the LH oil tube and the bolts.

    Torque

    : Stage 1: 71 lb.in (8 Nm) Stage 2: 45 °

GFD39919Courtesy of FORD MOTOR COMPANY

  1. 93.

    NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc ® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

    Make sure that the mating faces of the engine block are clean and free of foreign material.

    Material

    : Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material

    : Motorcraft ® Metal Surface Prep / ZC-31-B

  1. 94.

    Using the special tools, install the front cover to coolant pipe seal. Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing., 205-153 (T80T-4000-W) Handle.
GFD39652Courtesy of FORD MOTOR COMPANY

  1. 95.

    Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
GFD40028Courtesy 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 engine front cover and 6 bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover 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 to the engine front cover sealing surfaces including the inner bolt bosses.

      Material

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

    • 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 places as indicated.

      Material

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

GFD39654Courtesy of FORD MOTOR COMPANY

  1. 97.

    NOTE: Make sure the locating dowel pins are seated correctly in the cylinder block.

    Install the engine front cover and the bolts.

    Torque

    : 27 lb.in (3 Nm)

Fig 12: Engine Front Cover Bolts Tightening Sequence
GFD40029Courtesy of FORD MOTOR CO.

  1. 98.

    Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
GFD40030Courtesy of FORD MOTOR COMPANY

  1. 99.

    Install the remaining engine front cover bolts.

    Torque

    : Stage 1: Tighten bolts 1 thru 21 to: 89 lb.in (10 Nm) Stage 2: Tighten bolts 1 thru 20 to: 18 lb.ft (24 Nm) Stage 3: Tighten bolt 21 to: 177 lb.in (20 Nm) Stage 4: Tighten bolt 21 an additional: 90 ° Stage 5: Tighten bolt 22 to: 89 lb.in (10 Nm) Stage 6: Tighten bolt 22 an additional: 45 °

Fig 13: Engine Front Cover Bolts Tightening Sequence
GFD40031Courtesy of FORD MOTOR CO.

  1. 100.

    Install a new coolant pump gasket and O-ring seal.
GFD40032Courtesy of FORD MOTOR COMPANY

  1. 101.

    Install the coolant pump and the bolts.

    Torque

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

Fig 14: Coolant Pump Bolts Tightening Sequence
GFD40033Courtesy of FORD MOTOR CO.

  1. 102.

    Connect the CHT sensor electrical connector.
GFD39912Courtesy of FORD MOTOR COMPANY

  1. 103.

    Install the foam insulator.
GFD39911Courtesy of FORD MOTOR COMPANY

  1. 104.

    Install the new lower intake manifold gaskets.
GFD39710Courtesy of FORD MOTOR COMPANY

  1. 105.

    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 lower intake manifold and the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 15: Lower Intake Manifold Bolts Tightening Sequence
GFD40034Courtesy of FORD MOTOR CO.

  1. 106.

    Install a new thermostat housing O-ring seal.
GFD40035Courtesy of FORD MOTOR COMPANY

  1. 107.

    Install the thermostat housing and the bolts.

    Torque

    : Stage 1: 71 lb.in (8 Nm) Stage 2: 45 °

Fig 16: Thermostat Housing Bolts Tightening Sequence
GFD40036Courtesy of FORD MOTOR CO.

  1. 108.

    NOTE: Apply clean engine oil to the CMP sensor O-ring seals.

    Install the CMP sensors and the bolts.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

    Torque

    : 89 lb.in (10 Nm)

GFD39906Courtesy of FORD MOTOR COMPANY

  1. 109.

    Install the RH block coolant drain plug.

    Torque

    : Stage 1: 142 lb.in (16 Nm) Stage 2: 180 °

GFD39905Courtesy of FORD MOTOR COMPANY

  1. 110.

    Install the LH block coolant drain plug.

    Torque

    : 30 lb.ft (40 Nm)

GFD39904Courtesy of FORD MOTOR COMPANY

  1. 111.

    • Install the exhaust manifold studs.

      Torque

      : 106 lb.in (12 Nm)

    • Install the exhaust manifold gasket.
GFD40037Courtesy of FORD MOTOR COMPANY

  1. 112.

    Install the exhaust manifold and the new nuts.

    Torque

    : Stage 1: 168 lb.in (19 Nm) Stage 2: 18 lb.ft (25 Nm)

Fig 17: RH Exhaust Manifold Nuts Tightening Sequence
GFD40038Courtesy of FORD MOTOR CO.

  1. 113.

    Install the oil filter adapter and the bolts.

    Torque

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

Fig 18: Oil Filter Adapter Bolts Tightening Sequence
GFD40039Courtesy of FORD MOTOR CO.

  1. 114.

    Install the new oil cooler and bolt.

    Torque

    : 43 lb.ft (58 Nm)

GFD39899Courtesy of FORD MOTOR COMPANY

  1. 115.

    • Install the exhaust manifold studs.

      Torque

      : 106 lb.in (12 Nm)

    • Install the exhaust manifold gasket.
GFD40040Courtesy of FORD MOTOR COMPANY

  1. 116.

    Install the exhaust manifold and the new nuts.

    Torque

    : Stage 1: 168 lb.in (19 Nm) Stage 2: 18 lb.ft (25 Nm)

Fig 19: LH Exhaust Manifold Nuts Tightening Sequence
GFD40041Courtesy of FORD MOTOR CO.

  1. 117.

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

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

GFD39806Courtesy of FORD MOTOR COMPANY

  1. 118.

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

    If removed, using the special tools, install the VCT oil control solenoid seals. Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone., 205-153 (T80T-4000-W) Handle.

GFD39807Courtesy of FORD MOTOR COMPANY

  1. 119.

    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-cylinder head joints.

    Material

    : Motorcraft ® Metal Surface Prep / ZC-31-B

    Material

    : Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material

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

GFD40042Courtesy of FORD MOTOR COMPANY

  1. 120.

    Install a new valve cover gasket.
GFD39809Courtesy of FORD MOTOR COMPANY

  1. 121.

    Install the valve cover and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 20: RH Valve Cover Bolts Tightening Sequence
GFD40043Courtesy of FORD MOTOR CO.

  1. 122.

    Make sure 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.
GFD39811Courtesy of FORD MOTOR COMPANY

  1. 123.

    Install the RH coil-on-plugs and the bolts.

    Torque

    : 62 lb.in (7 Nm)

GFD39895Courtesy of FORD MOTOR COMPANY

  1. 124.

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

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

GFD39792Courtesy of FORD MOTOR COMPANY

  1. 125.

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

    If removed, using the special tools, install the VCT oil control solenoid seals. Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone., 205-153 (T80T-4000-W) Handle.

GFD39793Courtesy of FORD MOTOR COMPANY

  1. 126.

    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-cylinder head joints.

    Material

    : Motorcraft ® Metal Surface Prep / ZC-31-B

    Material

    : Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material

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

GFD40044Courtesy of FORD MOTOR COMPANY

  1. 127.

    Install a new valve cover gasket.
GFD39795Courtesy of FORD MOTOR COMPANY

  1. 128.

    Install the valve cover and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 21: LH Valve Cover Bolts Tightening Sequence
GFD40045Courtesy of FORD MOTOR CO.

  1. 129.

    Make sure 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.
GFD39797Courtesy of FORD MOTOR COMPANY

  1. 130.

    • Install the LH coil-on-plugs and the bolts.

      Torque

      : 62 lb.in (7 Nm)

    • Install the oil level indicator.
GFD39892Courtesy of FORD MOTOR COMPANY

  1. 131.

    • Install the engine wiring harness.
    • Connect the fuel injector electrical connectors.
GFD39891Courtesy of FORD MOTOR COMPANY

  1. 132.

    • Attach the wiring harness retainers.
    • Connect the CHT sensor electrical connector.
    • Connect the ignition coil-on-plug electrical connectors.
    • Connect the VCT oil control solenoids electrical connectors.
GFD39890Courtesy of FORD MOTOR COMPANY

  1. 133.

    Install the fuel rail sound insulators.
GFD39889Courtesy of FORD MOTOR COMPANY

  1. 134.

    • Attach the wiring harness retainers.
    • Connect the oil pressure switch electrical connector.
    • Connect the ignition coil-on-plug electrical connectors.
    • Disconnect the VCT oil control solenoids electrical connectors.
GFD39888Courtesy of FORD MOTOR COMPANY

  1. 135.

    • Attach the wiring harness retainers.
    • Connect the CMP sensor electrical connectors.
    • Connect the KS sensor electrical connector.
GFD39887Courtesy of FORD MOTOR COMPANY

  1. 136.

    Install the ground strap and the bolt.

    Torque

    : 106 lb.in (12 Nm)

GFD39886Courtesy of FORD MOTOR COMPANY

  1. 137.

    • Install the CKP sensor and the bolt.

      Torque

      : 89 lb.in (10 Nm)

    • Connect the CKP sensor electrical connector.
GFD39885Courtesy of FORD MOTOR COMPANY

  1. 138.

    Install the wiring harness grommet.
GFD39884Courtesy of FORD MOTOR COMPANY

  1. 139.

    Install the wiring harness retainer stud bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39883Courtesy of FORD MOTOR COMPANY

  1. 140.

    Install the heat shield, nut and bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39882Courtesy of FORD MOTOR COMPANY

  1. 141.

    NOTE: The bolt will be tighten after the installation of the upper intake manifold.

    Install the upper intake manifold support bracket and bolt finger tight.

GFD39881Courtesy of FORD MOTOR COMPANY

  1. 142.

    1. 1.

      Install the coolant pump pulley and the bolts.

      Torque

      : 18 lb.ft (24 Nm)

    1. 2.

      Install the accessory drive belt tensioner and the bolts.

      Torque

      : 18 lb.ft (25 Nm)

GFD39880Courtesy of FORD MOTOR COMPANY

  1. 143.

    Lubricate the crankshaft front seal bore with clean engine oil.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD40046Courtesy of FORD MOTOR COMPANY

  1. 144.

    Using the special tools, install the crankshaft front seal. Use Special Service Tool: 303-102 Installer, Crankshaft Pulley., 303-1251 Installer, Front Seal.
GFD40047Courtesy of FORD MOTOR COMPANY

  1. 145.

    Lubricate the crankshaft front seal and the crankshaft pulley with clean engine oil.

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD39584Courtesy of FORD MOTOR COMPANY

  1. 146.

    Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-102 Installer, Crankshaft Pulley., 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal.
GFD40048Courtesy of FORD MOTOR COMPANY

  1. 147.

    Install the new crankshaft bolt and the washer. Use the General Equipment: Strap Wrench

    Torque

    : Stage 1: 89 lb.ft (120 Nm) Stage 2: Loosen:: 1 turn(s) Stage 3: 37 lb.ft (50 Nm) Stage 4: 90 °

GFD40049Courtesy of FORD MOTOR COMPANY

  1. 148.

    Install the degas bottle hose. Use the General Equipment: Hose Clamp Remover/Installer
GFD39876Courtesy of FORD MOTOR COMPANY

  1. 149.

    NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.

    Install the LH engine mount bracket and the bolts.

    Torque

    : 46 lb.ft (63 Nm)

GFD39875Courtesy of FORD MOTOR COMPANY

  1. 150.

    NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.

    Install the RH engine mount bracket and the bolts.

    Torque

    : 57 lb.ft (77 Nm)

GFD39874Courtesy of FORD MOTOR COMPANY

  1. 151.

    Install the RH engine mount and the bolt.

    Torque

    : 258 lb.ft (350 Nm)

GFD39873Courtesy of FORD MOTOR COMPANY

  1. 152.

    Install Special Service Tool: 303-1245 Engine Lift Eye.
GFD39664Courtesy of FORD MOTOR COMPANY

  1. 153.

    Install the RH lift eye and the bolts.

    Torque

    : 25 lb.ft (34 Nm)

GFD39872Courtesy of FORD MOTOR COMPANY

  1. 154.

    Install the A/C compressor and the bolts.

    Torque

    : 18 lb.ft (25 Nm)

GFD39871Courtesy of FORD MOTOR COMPANY

  1. 155.

    Install the floor crane and chain. Use the General Equipment: Floor Crane
GFD39870Courtesy of FORD MOTOR COMPANY

  1. 156.

    Remove the engine from the mounting stand. Use the General Equipment: Mounting Stand
GFD40050Courtesy of FORD MOTOR COMPANY

  1. 157.

    Install the crankshaft sensor ring and the engine-to-transmission spacer plate.
GFD39587Courtesy of FORD MOTOR COMPANY

  1. 158.

    NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.

    Install the flexplate and the bolts.

    Torque

    : 59 lb.ft (80 Nm)

Fig 22: Flexplate Bolts Tightening Sequence
GFD40051Courtesy of FORD MOTOR CO.
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