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Section 677 (ENGINE - 3.5L ECOBOOST (272kW/370PS)): 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
GFD39292Courtesy of FORD MOTOR COMPANY
 303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD39257Courtesy of FORD MOTOR COMPANY
 303-1247VCT 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
Round-Ended Steel Rule
Piston Ring Compressor

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
Motorcraft ® Silicone Gasket Remover ZC-30-A -
Flange Sealant CU7Z-19B508-A WSS-M2G348-A11
Motorcraft ® Metal Surface Prep ZC-31-B -
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
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 .
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed. Refer to Variable Camshaft Timing (VCT) Unit .

  1. 1.

    Using a hexagonal screwdriver, 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-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-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-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-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-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-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 Cap 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

    Material

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

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-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

GFD39595Courtesy of FORD MOTOR COMPANY

  1. 30.

    Install the crankshaft rear seal retainer and the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 4: Crankshaft Rear Seal Retainer 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 the pickup tube O-ring seal.
GFD39761Courtesy of FORD MOTOR COMPANY

  1. 33.

    Install the oil pump screen and the 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 below. 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. Tighten in the sequence shown below.

    Torque

    : Stage 1: Tighten bolts 1-9 and 11-14 to: 18 lb.ft (24 Nm) Stage 2: Tighten bolt 10 to: 177 lb.in (20 Nm) Stage 3: Tighten bolt 10 an additional: 90 ° Stage 4: Tighten bolts 15 and 16 to: 89 lb.in (10 Nm)

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

  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 LH 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
GFD40091Courtesy of FORD MOTOR CO.

  1. 44.

    Install the LH 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 RH 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
GFD40099Courtesy of FORD MOTOR CO.

  1. 47.

    Install the RH M6 bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD39633Courtesy of FORD MOTOR COMPANY

  1. 48.

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

    Install the valve tappets.

    Material

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

GFD40100Courtesy of FORD MOTOR COMPANY

  1. 49.

    Install the RH primary timing chain guide and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD40094Courtesy 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 below.

    Material

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

GFD40070Courtesy 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 below.

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 Bearing Cap Bolts Tightening Sequence
GFD40071Courtesy of FORD MOTOR CO.

  1. 54.

    Loosen the camshaft cap bolts.
GFD40072Courtesy of FORD MOTOR COMPANY

  1. 55.

    Tighten the camshaft cap bolts.

    Torque

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

GFD40073Courtesy 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.

    Apply 8mm dots of sealant to the camshaft bearing cap as shown below.

    Material

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

GFD40074Courtesy of FORD MOTOR COMPANY

  1. 58.

    Install the camshaft bearing cap and bolts.

    Torque

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

GFD40068Courtesy of FORD MOTOR COMPANY

  1. 59.

    Remove the bolts and the oil tube.
GFD39566Courtesy of FORD MOTOR COMPANY

  1. 60.

    Rotate the RH camshafts to TDC.
GFD40076Courtesy of FORD MOTOR COMPANY

  1. 61.

    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. 62.

    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. 63.

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

  1. 64.

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

    Position the RHVCT 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. 65.

    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. 66.

    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. 67.

    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 below.

    Material

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

GFD39568Courtesy of FORD MOTOR COMPANY

  1. 68.

    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 below.

GFD39569Courtesy of FORD MOTOR COMPANY

  1. 69.

    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 Bearing Cap Bolts Tightening Sequence
GFD40329Courtesy of FORD MOTOR CO.

  1. 70.

    Loosen the camshaft cap bolts.
GFD40330Courtesy of FORD MOTOR COMPANY

  1. 71.

    Tighten the camshaft cap bolts.

    Torque

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

GFD40331Courtesy of FORD MOTOR COMPANY

  1. 72.

    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. 73.

    Remove bolts and the oil tube.
GFD39574Courtesy of FORD MOTOR COMPANY

  1. 74.

    Rotate the LH camshafts to TDC.
GFD39575Courtesy of FORD MOTOR COMPANY

  1. 75.

    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. 76.

    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. 77.

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

  1. 78.

    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. 79.

    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. 80.

    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. 81.

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

    Torque

    : 89 lb.in (10 Nm)

GFD39923Courtesy of FORD MOTOR COMPANY

  1. 82.

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

  1. 83.

    Install the crankshaft sprocket.
GFD39768Courtesy of FORD MOTOR COMPANY

  1. 84.

    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. 85.

    Install the lower LH timing chain guide and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD39751Courtesy of FORD MOTOR COMPANY

  1. 86.

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

  1. 87.

    1. 1.

      Release the ratchet detent.

    1. 2.

      Using a soft-jawed vise, compress the ratchet plunger.

    1. 3.

      Align the hole in the ratchet plunger with the hole in the tensioner housing and install a lockpin.
GFD40214Courtesy of FORD MOTOR COMPANY

  1. 88.

    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.
GFD40215Courtesy of FORD MOTOR COMPANY

  1. 89.

    • 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. 90.

    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. 91.

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

  1. 92.

    Install the RH oil tube and the bolts.

    Torque

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

GFD39566Courtesy of FORD MOTOR COMPANY

  1. 93.

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

  1. 94.

    Install the LH oil tube and the bolts.

    Torque

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

GFD39574Courtesy of FORD MOTOR COMPANY

  1. 95.

    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. 96.

    Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
GFD40028Courtesy of FORD MOTOR COMPANY

  1. 97.

    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. 98.

    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. 99.

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

  1. 100.

    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. 101.

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

  1. 102.

    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
GFD40332Courtesy of FORD MOTOR CO.

  1. 103.

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

    Install the CMP sensors and the bolts.

    Material

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

    Torque

    : 89 lb.in (10 Nm)

GFD40088Courtesy of FORD MOTOR COMPANY

  1. 104.

    NOTE: Installation of new seals is only required if damaged seals were removed.
    NOTE: RH shown, LH similar.

    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. 105.

    NOTE: Installation of new seals is only required if damaged seals were removed.
    NOTE: RH shown, LH similar.

    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. 106.

    Install a new RH valve cover gasket.
GFD40236Courtesy of FORD MOTOR COMPANY

  1. 107.

    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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

    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. 108.

    Install the RH valve cover and the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 15: RH Valve Cover Bolts Tightening Sequence
GFD40333Courtesy of FORD MOTOR CO.

  1. 109.

    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. 110.

    Install a new LH valve cover gasket.
GFD40223Courtesy of FORD MOTOR COMPANY

  1. 111.

    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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

    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. 112.

    Install the LH valve cover and the bolts.

    Torque

    : 89 lb.in (10 Nm)

Fig 16: LH Valve Cover Bolts Tightening Sequence
GFD40334Courtesy of FORD MOTOR CO.

  1. 113.

    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. 114.

    Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before installing.

    Material

    : Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

GFD40335Courtesy of FORD MOTOR COMPANY

  1. 115.

      NOTE: Apply clean engine oil to the CMP sensor O-ring seals.
    • Install the CMP sensors and the bolts.

      Material

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

      Torque

      : 71 lb.in (8 Nm)

    • Install all of the coil-on-plugs and the bolts.

      Torque

      : Stage 1: 62 lb.in (7 Nm) Stage 2: 50 °

GFD40301Courtesy of FORD MOTOR COMPANY

  1. 116.

    • Install the engine wiring harness attach all of the wiring harness retainers.
    • Connect the coil-on-plug electrical connectors.
    • Connect the CMP sensor electrical connectors.
    • Connect the VCT sensor electrical connectors.
GFD40300Courtesy of FORD MOTOR COMPANY

  1. 117.

    • Attach the wiring harness retainers.
    • Connect the coil-on-plug electrical connectors.
    • Connect the VCT sensor electrical connectors.
    • Install the oil level indicator.
GFD40299Courtesy of FORD MOTOR COMPANY

  1. 118.

    • Install the CKP sensor and bolt.

      Torque

      : 89 lb.in (10 Nm)

    • Connect the CKP sensor electrical connector.
GFD40298Courtesy of FORD MOTOR COMPANY

  1. 119.

    • Attach the wiring harness grommet to the cylinder block.
    • Install the stud bolt.

      Torque

      : 89 lb.in (10 Nm)

GFD40297Courtesy of FORD MOTOR COMPANY

  1. 120.

    Remove the nut, bolt and the heat shield.

    Torque

    : 89 lb.in (10 Nm)

GFD40296Courtesy of FORD MOTOR COMPANY

  1. 121.

    • Install the ground wire and stud bolt.

      Torque

      : Stage 1: 89 lb.in (10 Nm) Stage 2: 20 °

    • Attach the wiring harness retainer and if equipped, install the nut.

      Torque

      : 89 lb.in (10 Nm)

    • Connect the CMP sensor electrical connectors.
    • Install the ground strap and the bolt.

      Torque

      : 97 lb.in (11 Nm)

GFD40295Courtesy of FORD MOTOR COMPANY

  1. 122.

    • Connect the RH and LH fuel charge harness electrical connectors.
    • Connect the fuel pressure sensor electrical connector.
    • Connect the KS electrical connector.
GFD40294Courtesy of FORD MOTOR COMPANY

  1. 123.

    • Install the ground wire and stud bolt.

      Torque

      : Stage 1: 89 lb.in (10 Nm) Stage 2: 20 °

    • Connect the CHT sensor electrical connector and wiring harness retainer.
GFD40293Courtesy of FORD MOTOR COMPANY

  1. 124.

    NOTE: Make sure that the mating faces are clean and free of foreign material.

    Clean the surface and apply an 8mm bead of sealer.

    Material

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

    Material

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

GFD40336Courtesy of FORD MOTOR COMPANY

  1. 125.

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

    Install the vacuum pump and the bolts.

    Torque

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

Fig 17: Vacuum Pump Bolts Tightening Sequence
GFD40337Courtesy of FORD MOTOR CO.

  1. 126.

    Install the heat shield, bolt and nut.

    Torque

    : 89 lb.in (10 Nm)

GFD40338Courtesy of FORD MOTOR COMPANY

  1. 127.

    Install the RH block coolant drain plug.

    Torque

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

GFD40290Courtesy of FORD MOTOR COMPANY

  1. 128.

    Install the LH block coolant drain plug.

    Torque

    : 30 lb.ft (40 Nm)

GFD40289Courtesy of FORD MOTOR COMPANY

  1. 129.

    NOTE: Tighten the upper bolts first.

    Install the oil filter adapter and the bolts.

    Torque

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

GFD40288Courtesy of FORD MOTOR COMPANY

  1. 130.

    NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

    Install the new oil cooler and the bolt.

    Torque

    : 43 lb.ft (58 Nm)

GFD40339Courtesy of FORD MOTOR COMPANY

  1. 131.

    Connect the oil pressure switch and the wire retainer.
GFD40286Courtesy of FORD MOTOR COMPANY

  1. 132.

    Install the generator stud bolt.

    Torque

    : 71 lb.in (8 Nm)

GFD40285Courtesy of FORD MOTOR COMPANY

  1. 133.

    Install the generator, nut and bolt.

    Torque

    : 35 lb.ft (48 Nm)

GFD40284Courtesy of FORD MOTOR COMPANY

  1. 134.

    Install the CAC tube bracket and the nuts.

    Torque

    : M6 nut : 53 lb.in (6 Nm) M10 nut : 133 lb.in (15 Nm)

GFD40283Courtesy of FORD MOTOR COMPANY

  1. 135.

      NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.
    • Install a new O-ring seal.

      Material

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

    • Install a new gasket.
GFD40340Courtesy of FORD MOTOR COMPANY

  1. 136.

      NOTE: Install the oil return tube into the cylinder block bore prior to installing the turbocharger bolts.
    • Install the LH turbocharger and the bolts.

      Torque

      : 24 lb.ft (32 Nm)

    • Install the oil return tube bolt.

      Torque

      : Stage 1: 71 lb.in (8 Nm) Stage 2: 30 °

    • Install the coolant/oil tube assembly bolt.

      Torque

      : Stage 1: 71 lb.in (8 Nm) Stage 2: 30 °

GFD40341Courtesy of FORD MOTOR COMPANY

  1. 137.

    Install the LH turbocharger coolant return tube and fitting into the cylinder head.

    Torque

    : 159 lb.in (18 Nm)

GFD40280Courtesy of FORD MOTOR COMPANY

  1. 138.

      NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.
    • Install a new O-ring seal.

      Material

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

    • Install a new gasket.
GFD40342Courtesy of FORD MOTOR COMPANY

  1. 139.

      NOTE: Install the oil return tube into the cylinder block bore prior to installing the turbocharger bolts.
    • Install the RH turbocharger and the bolts.

      Torque

      : 24 lb.ft (32 Nm)

    • Install the oil return tube bolt.

      Torque

      : Stage 1: 71 lb.in (8 Nm) Stage 2: 30 °

    • Install the coolant/oil tube assembly bolt.

      Torque

      : Stage 1: 71 lb.in (8 Nm) Stage 2: 30 °

GFD40343Courtesy of FORD MOTOR COMPANY

  1. 140.

    Install the RH turbocharger coolant return tube and fitting into the cylinder head.

    Torque

    : 159 lb.in (18 Nm)

GFD40277Courtesy of FORD MOTOR COMPANY

  1. 141.

    NOTE: Apply clean engine oil to the threads of the high-pressure fuel tube flare nuts.
    • Position the high-pressure fuel tube and hand start the flare nuts and bracket bolt.

      Material

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

    • Tighten the High-pressure fuel tube-to-RH fuel rail flare nut in 3 stages:

      Torque

      : Stage 1: 133 lb.in (15 Nm) Stage 2: 30 ° Stage 3: 24 lb.ft (32 Nm)

    • Tighten the High-pressure fuel tube-to-LH fuel rail flare nut in 3 stages:

      Torque

      : Stage 1: 133 lb.in (15 Nm) Stage 2: 30 ° Stage 3: 24 lb.ft (32 Nm)

    • Tighten the high-pressure fuel tube bracket bolt in 2 stages.

      Torque

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

GFD40344Courtesy of FORD MOTOR COMPANY

  1. 142.

    Install new gaskets.
GFD40345Courtesy of FORD MOTOR COMPANY

  1. 143.

    Install the coolant outlet and the bolts.

    Torque

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

GFD40274Courtesy of FORD MOTOR COMPANY

  1. 144.

    • Install new O-ring seals.
    • Install the coolant pipe.
GFD40346Courtesy of FORD MOTOR COMPANY

  1. 145.

    If necessary, install a new O-ring seal.
GFD40347Courtesy of FORD MOTOR COMPANY

  1. 146.

    Install the thermostat housing and the bolts.

    Torque

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

Fig 18: Thermostat Housing Bolts Tightening Sequence
GFD40348Courtesy of FORD MOTOR CO.

  1. 147.

    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)

GFD40271Courtesy of FORD MOTOR COMPANY

  1. 148.

    Lubricate the crankshaft front seal bore with clean engine oil.

    Material

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

GFD40046Courtesy of FORD MOTOR COMPANY

  1. 149.

    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. 150.

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

    Material

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

GFD39584Courtesy of FORD MOTOR COMPANY

  1. 151.

    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. 152.

    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. 153.

    • Attach the vacuum hose retainers to the valve covers.
    • Connect the electrical connector to the vacuum solenoid.
    • Connect the vacuum hoses to the turbochargers.
GFD40270Courtesy of FORD MOTOR COMPANY

  1. 154.

    Install the PCV tube.
GFD40269Courtesy of FORD MOTOR COMPANY

  1. 155.

    Install the LH engine mount bracket and the bolts.

    Torque

    : For standard payload package : 46 lb.ft (63 Nm) For heavy duty payload package : 57 lb.ft (77 Nm)

GFD40349Courtesy of FORD MOTOR COMPANY

  1. 156.

    Install the RH engine mount bracket and the bolts.

    Torque

    : 57 lb.ft (77 Nm)

GFD40350Courtesy of FORD MOTOR COMPANY

  1. 157.

    Install the RH engine mount and the bolt.

    Torque

    : 258 lb.ft (350 Nm)

GFD40351Courtesy of FORD MOTOR COMPANY

  1. 158.

    Install the A/C compressor and the bolts.

    Torque

    : 18 lb.ft (25 Nm)

GFD40265Courtesy of FORD MOTOR COMPANY

  1. 159.

    NOTE: Use a quick link on the RH side from the engine to the engine spreader bar.

    Install Special Service Tool: 303-1246 Engine Spreader Bar. Use the General Equipment: Floor Crane

GFD40264Courtesy of FORD MOTOR COMPANY

  1. 160.

    Remove the engine from the mounting stand. Use the General Equipment: Mounting Stand
GFD40263Courtesy of FORD MOTOR COMPANY

  1. 161.

    Install the crankshaft sensor ring and the engine-to-transmission spacer plate.
GFD40083Courtesy of FORD MOTOR COMPANY

  1. 162.

    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 19: Flexplate Bolts Tightening Sequence
GFD40161Courtesy of FORD MOTOR CO.
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