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Section 678 (Engine - 5.0L 32V Ti-VCT): Assembly: Engine

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Special Tool(s) / General Equipment 

GFD39783Courtesy of FORD MOTOR COMPANY
 205-142 (T80T-4000-J) Installer, Differential Bearing Cone
GFD38522Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W) Handle
GFD39257Courtesy of FORD MOTOR COMPANY
 303-1247VCT Spark Plug Tube Seal Remover and Installer

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
GFD39088Courtesy of FORD MOTOR COMPANY
 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal

TKIT-1988-F

TKIT-1988-FLM
GFD40537Courtesy of FORD MOTOR COMPANY
 303-448 (T93P-6303-A) Holding Tool, Crankshaft

TKIT-1993-FLM

TKIT-1993-LM
GFD40594Courtesy of FORD MOTOR COMPANY
 303-F047 Lifting Bracket, Engine
Strap Wrench
Floor Crane
Mounting Stand
Piston Ring Compressor

Materials 

Name Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C945-A
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Motorcraft® Orange Concentrated Antifreeze/CoolantVC-3-B WSS-M97B44-D
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
NOTE: The timing chain alignment procedure has changed from prior model year engines and must be followed exactly or damage to the engine will result.
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: During engine assembly it may become necessary to check bearing clearances and end play. Refer to appropriate Engine article.

  1. 1.

    Record the main bearing code found on the front of the engine block.
GFD40687Courtesy of FORD MOTOR COMPANY

  1. 2.

    Record the main bearing code found on the rear of the crankshaft.
GFD40688Courtesy of FORD MOTOR COMPANY

  1. 3.

    NOTE: This chart is for selecting main bearings 1 and 5 only, the remaining bearings will be selected using a different chart in the next step.

    Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 5.

    • 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 "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing.
    • Repeat the above steps using the fifth letter of the block and crankshaft codes to select the No. 5 bearing.
GFD40689Courtesy of FORD MOTOR COMPANY

  1. 4.

    NOTE: This chart is for selecting main bearings 2, 3 and 4 only.

    Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2, 3 and 4.

    • 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(s) for the No. 2 crankshaft main bearing.
    • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing
    • Repeat the above steps using the third and fourth letters of the block and crankshaft codes to select the No. 3 and No. 4 bearings.
GFD40690Courtesy of FORD MOTOR COMPANY

  1. 5.

    Install the piston cooling jets and bolts.

    Torque:

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 45°

GFD40662Courtesy of FORD MOTOR COMPANY

  1. 6.

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

      Material

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

GFD40691Courtesy of FORD MOTOR COMPANY

  1. 7.

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

    Install the crankshaft into the cylinder block.

    Material

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

GFD40692Courtesy of FORD MOTOR COMPANY

  1. 8.

    NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft thrust surface).
    NOTE: Lubricate the thrust washer with clean engine oil.

    Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.

    Material

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

GFD40693Courtesy of FORD MOTOR COMPANY

  1. 9.

    NOTE: Lubricate the fastener threads with clean engine oil.

    Install the main bearing caps and fasteners on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the cap fasteners.

    Material

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

GFD40694Courtesy of FORD MOTOR COMPANY

  1. 10.

    Push the crankshaft forward to seat the crankshaft thrust washer.
GFD40695Courtesy of FORD MOTOR COMPANY

  1. 11.

    Tighten the vertical main bearing cap fasteners.

    Torque:

    Stage 1: 1 through 20: 177 lb.in (20 Nm)

    Stage 2: 1 through 10: 30 lb.ft (40 Nm)

    Stage 3: 11 through 20 : 48 lb.ft (65 Nm)

    Stage 4: 1 through 20: 90°

Fig 1: Main Bearing Tightening Sequence (1 Of 2)
GFD40696Courtesy of FORD MOTOR COMPANY

  1. 12.

    Install the cross-mounted main bearing cap fasteners.

    Torque:

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 22 lb.ft (30 Nm)

    Stage 3: 60°

Fig 2: Main Bearing Tightening Sequence (2 Of 2)
GFD40697Courtesy of FORD MOTOR COMPANY

  1. 13.

    • Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
    • 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. 14.

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

    Material

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

GFD40698Courtesy of FORD MOTOR COMPANY

  1. 15.

    NOTE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.
    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: 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 piston with clean engine oil.
    • Using a piston ring compressor, install the piston.

      Use the General Equipment: Piston Ring Compressor

      Material

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

GFD40699Courtesy 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.

    Install the connecting rod cap and bearing.

    • Install the new bolts hand tight.
GFD40700Courtesy of FORD MOTOR COMPANY

  1. 17.

    Repeat the previous 2 steps for each of the remaining pistons.

  1. 18.

    Tighten the connecting rod bolts.

    Torque:

    Stage 1: 177 lb.in (20 Nm)

    Stage 2: 28 lb.ft (38 Nm)

    Stage 3: 105°

Fig 3: Connecting Rod Tightening Sequence
GFD40701Courtesy of FORD MOTOR COMPANY

  1. 19.

    NOTE: Oil pump must be held against the cylinder block until all bolts are tightened.
    • Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil pump over the crankshaft until seated against the block.
    • Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners hand tight.

      Torque:

      Stage 1: A: 89 lb.in (10 Nm)

      Stage 2: B: 18 lb.ft (25 Nm)

      Stage 3: C: 89 lb.in (10 Nm)

      Stage 4: D: 177 lb.in (20 Nm)

      Stage 5: A: 45°

      Stage 6: B: 75°

      Stage 7: C: 45°

      Stage 8: D: 60°

GFD40535Courtesy of FORD MOTOR COMPANY

  1. 20.

    NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. Failure to follow this procedure may cause future oil leaks.

    Apply a 3.75 mm (0.147 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating surface on the engine block.

    Material

    : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

GFD40398Courtesy of FORD MOTOR COMPANY

  1. 21.

    Install the crankshaft rear seal retainer plate and the bolts.

    Torque:

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 45°

GFD40399Courtesy of FORD MOTOR COMPANY

  1. 22.

    Install the oil pump screen and pickup tube spacer.

    Torque

    : 18 lb.ft (25 Nm)

GFD40654Courtesy of FORD MOTOR COMPANY

  1. 23.

    Using a new O-ring seal, install the oil pump screen and pickup tube and the bolts.

    Torque:

    Oil pump screen and pickup tube-to-oil pump bolts : Stage 1: 89 lb.in (10 Nm)

    Stage 2: 45°

    Oil pump screen and pickup tube-to-spacer bolt : 18 lb.ft (25 Nm)

GFD40536Courtesy of FORD MOTOR COMPANY

  1. 24.

    NOTE: If the oil pan is not installed and the fasteners tightened within 5 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. If this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque all of the fasteners within 1 hour of applying the sealer.

    Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces.

    Material

    : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    Torque

    : 18 lb.ft (25 Nm)

GFD40702Courtesy of FORD MOTOR COMPANY

  1. 25.

    Install a new gasket, the oil pan and the fasteners.

    Torque:

    Stage 1: 18 lb.in (2 Nm)

    Stage 2: 89 lb.in (10 Nm)

    Stage 3: 45°

GFD40703Courtesy of FORD MOTOR COMPANY

  1. 26.

    Install the A/C compressor and the bolts.

    Torque

    : 18 lb.ft (25 Nm)

GFD40652Courtesy of FORD MOTOR COMPANY

  1. 27.

    Install a new oil filter adapter gasket.
GFD40704Courtesy of FORD MOTOR COMPANY

  1. 28.

    Install the oil filter adapter and the bolts.

    Torque:

    Stage 1: 177 lb.in (20 Nm)

    Stage 2: 60°

GFD40650Courtesy of FORD MOTOR COMPANY

  1. 29.

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

    Install a new oil cooler and the threaded fitting.

    Torque

    : 43 lb.ft (58 Nm)

GFD40705Courtesy of FORD MOTOR COMPANY

  1. 30.

    NOTE: The CKP sensor must be positioned into the fitting on the crankshaft rear seal retainer plate and be flush against the boss on the engine block before the bolt is installed. If the CKP sensor is installed incorrectly, the CKP sensor can be damaged.
    • Install the CKP sensor must be positioned into the fitting on the crankshaft rear seal retainer plate.
    • Make sure the CKP sensor is flush with the engine block boss.
    • Install the bolt.

      Torque

      : 89 lb.in (10 Nm)

GFD40706Courtesy of FORD MOTOR COMPANY

  1. 31.

    Install the KSs and the bolts.

    Torque

    : 177 lb.in (20 Nm)

GFD40647Courtesy of FORD MOTOR COMPANY

  1. 32.

    Install the dowels on the LH bank of the cylinder block.
GFD40646Courtesy of FORD MOTOR COMPANY

  1. 33.

    Install a new LH cylinder head gasket.
GFD40406Courtesy of FORD MOTOR COMPANY

  1. 34.

    NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

    Install the LH cylinder head and the new bolts.

    Torque:

    Stage 1: 18 lb.ft (25 Nm)

    Stage 2: 55 lb.ft (75 Nm)

    Stage 3: Loosen: 180°

    Stage 4: 18 lb.ft (25 Nm)

    Stage 5: 26 lb.ft (35 Nm)

    Stage 6: 90°

    Stage 7: 90°

GFD40407Courtesy of FORD MOTOR COMPANY
NOTE: The LH camshafts, VCT units and timing chains must be installed first. Only turn the crankshaft as instructed. Failure to do so may result in the camshafts installed out of phase and serious damage to the engine will result.

  1. 35.

    NOTE: If the components are to be reinstalled, they must be installed in their original locations.

    1. 1.

      Assemble the hydraulic lash adjusters onto the spring clips on the camshaft roller followers.

    1. 2.

      Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil.

      Material

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

    1. 3.

      Install the camshaft roller follower and hydraulic lash adjuster assemblies.
GFD40367Courtesy of FORD MOTOR COMPANY

  1. 36.

    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-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD40368Courtesy of FORD MOTOR COMPANY

  1. 37.

    Install the camshaft bearing caps and the bolts. Do not tighten at this time.
GFD40364Courtesy of FORD MOTOR COMPANY

  1. 38.

    Install the front camshaft bearing mega cap and the bolts. Do not tighten at this time.
GFD40363Courtesy of FORD MOTOR COMPANY

  1. 39.

    Tighten the bolts.

    Torque:

    Stage 1: 53 lb.in (6 Nm)

    Stage 2: 45°

GFD40369Courtesy of FORD MOTOR COMPANY

  1. 40.

    Install new VCT system oil filters into the camshafts.
GFD40370Courtesy of FORD MOTOR COMPANY

  1. 41.

    Position the secondary timing chain onto the VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
    • The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
    • The timing mark on the exhaust VCT assembly should align with the single colored link.
GFD40588Courtesy of FORD MOTOR COMPANY

  1. 42.

    Install the VCT assemblies and the secondary timing chain onto the camshafts. The timing mark on the exhaust VCT assembly should be approximately in the 1 o'clock position.
GFD40589Courtesy of FORD MOTOR COMPANY

  1. 43.

    NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.

    Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.

    • If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.
GFD40590Courtesy of FORD MOTOR COMPANY

  1. 44.

    NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

    Install the intake and the exhaust VCT assembly bolts.

    Torque:

    Stage 1: 133 lb.in (15 Nm)

    Stage 2: 90°

GFD40584Courtesy of FORD MOTOR COMPANY

  1. 45.

    Install the crankshaft sprocket.
GFD40532Courtesy of FORD MOTOR COMPANY

  1. 46.

    Install the LH timing chain.
    • Align the colored link on the timing chain with the timing mark on the LHVCT assembly.
    • Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
GFD40550Courtesy of FORD MOTOR COMPANY

  1. 47.

    NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain guide. Return the crankshaft keyway to the 3:30 position after installing the LH timing chain guide.

    Install the LH timing chain guide and bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD40548Courtesy of FORD MOTOR COMPANY

  1. 48.

    NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain arm. Return the crankshaft keyway to the 3:30 position after installing the LH timing chain arm.

    Install the LH timing chain tensioner arm.

GFD40547Courtesy of FORD MOTOR COMPANY

  1. 49.

    1. 1.

      Compress the primary timing chain tensioner plunger, using an edge of a vise.

    1. 2.

      Install a suitable pin into the hole of the tensioner housing to hold the plunger in place during installation.
GFD40551Courtesy of FORD MOTOR COMPANY

  1. 50.

    1. 1.

      Install the LH primary timing chain tensioner and bolts.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Remove the holding pin from the tensioner.
GFD40552Courtesy of FORD MOTOR COMPANY

  1. 51.

    Using the special tool, rotate the crankshaft clockwise until the keyway is at the 7:30 position.

    Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.

GFD40553Courtesy of FORD MOTOR COMPANY

  1. 52.

    Install the dowels on the RH bank of the cylinder block.
GFD40645Courtesy of FORD MOTOR COMPANY

  1. 53.

    Install the new cylinder head gasket.
GFD40416Courtesy of FORD MOTOR COMPANY

  1. 54.

    NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

    Install the cylinder head and the new bolts.

    Torque:

    Stage 1: 18 lb.ft (25 Nm)

    Stage 2: 55 lb.ft (75 Nm)

    Stage 3: Loosen: 180°

    Stage 4: 18 lb.ft (25 Nm)

    Stage 5: 26 lb.ft (35 Nm)

    Stage 6: 90°

    Stage 7: 90°

GFD40417Courtesy of FORD MOTOR COMPANY

  1. 55.

    NOTE: If the components are to be reinstalled, they must be installed in their original locations.

    1. 1.

      Assemble the hydraulic lash adjusters onto the spring clips on the camshaft roller followers.

    1. 2.

      Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil.

      Material

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

    1. 3.

      Install the camshaft roller follower and hydraulic lash adjuster assemblies.
GFD40376Courtesy of FORD MOTOR COMPANY

  1. 56.

    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-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD40377Courtesy of FORD MOTOR COMPANY

  1. 57.

    Install the camshaft bearing caps and the bolts. Do not tighten at this time.
GFD40373Courtesy of FORD MOTOR COMPANY

  1. 58.

    Install the front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time.
GFD40372Courtesy of FORD MOTOR COMPANY

  1. 59.

    Tighten the bolts.

    Torque:

    Stage 1: 53 lb.in (6 Nm)

    Stage 2: 45°

GFD40378Courtesy of FORD MOTOR COMPANY

  1. 60.

    Install new VCT system oil filters into the camshafts.
GFD40379Courtesy of FORD MOTOR COMPANY

  1. 61.

    Position the secondary timing chain onto the VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
    • The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
    • The timing mark on the exhaust VCT assembly should align with the single colored link.
GFD40591Courtesy of FORD MOTOR COMPANY

  1. 62.

    Install the VCT assemblies and the secondary timing chain onto the camshafts. The timing mark on the exhaust VCT assembly should be approximately in the 11 o'clock position.
GFD40592Courtesy of FORD MOTOR COMPANY

  1. 63.

    NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.

    Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.

    • If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.
GFD40593Courtesy of FORD MOTOR COMPANY

  1. 64.

    NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

    Install the intake and the exhaust VCT assembly bolts.

    Torque:

    Stage 1: 133 lb.in (15 Nm)

    Stage 2: 90°

GFD40580Courtesy of FORD MOTOR COMPANY

  1. 65.

    Install the RH timing chain.
    • Align the colored link on the timing chain with the timing mark on the RHVCT assembly.
    • Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
GFD40554Courtesy of FORD MOTOR COMPANY

  1. 66.

    NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain guide. Return the crankshaft keyway to the 7:30 position after installing the RH timing chain guide.

    Install the RH timing chain guide and bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD40542Courtesy of FORD MOTOR COMPANY

  1. 67.

    NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain arm. Return the crankshaft keyway to the 7:30 position after installing the RH timing chain arm.

    Install the RH timing chain tensioner arm.

GFD40541Courtesy of FORD MOTOR COMPANY

  1. 68.

    1. 1.

      Compress the primary timing chain tensioner plunger, using an edge of a vise.

    1. 2.

      Install a suitable pin into the hole of the tensioner housing to hold the plunger in place during installation.
GFD40551Courtesy of FORD MOTOR COMPANY

  1. 69.

    1. 1.

      Install the RH primary timing chain tensioner and bolts.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Remove the holding pin from the tensioner.
GFD40555Courtesy of FORD MOTOR COMPANY

  1. 70.

    Install new gaskets on the engine front cover.
GFD40438Courtesy of FORD MOTOR COMPANY

  1. 71.

    NOTE: The VCT variable force solenoid pins must be fully depressed to avoid interference with the VCT valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.
    NOTE: RH shown in illustration, LH similar.

    Fully depress the VCT variable force solenoid pins.

GFD40439Courtesy of FORD MOTOR COMPANY

  1. 72.

    NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

    Apply a 15 mm (0.59 in) diameter drop of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints.

    Material

    : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

GFD40440Courtesy of FORD MOTOR COMPANY

  1. 73.

    NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.

    Position the engine front cover onto the dowels.

GFD40707Courtesy of FORD MOTOR COMPANY

  1. 74.

    NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

    Install the bolts and stud bolts.

    Torque:

    Stage 1: Fasteners 1-15 : 18 lb.ft (25 Nm)

    Stage 2: Fasteners 16-19 : 89 lb.in (10 Nm)

    Stage 3: Fasteners 1-15 : 60°

    Stage 4: Fasteners 16-19 : 45°

GFD40442Courtesy of FORD MOTOR COMPANY

  1. 75.

    Using a 10 mm Hex Bit, turn the engine front cover-to-oil filter adapter jack screw into contact with the oil filter adapter.

    Torque

    : 44 lb.in (5 Nm)

GFD40433Courtesy of FORD MOTOR COMPANY

  1. 76.

    Install the engine front cover-to-oil filter adapter bolt.

    Torque:

    Stage 1: 18 lb.ft (25 Nm)

    Stage 2: 60°

GFD40432Courtesy of FORD MOTOR COMPANY

  1. 77.

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

    Material

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

GFD40383Courtesy 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.

GFD40384Courtesy of FORD MOTOR COMPANY

  1. 79.

    NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

    Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.

    Material

    : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

GFD40385Courtesy of FORD MOTOR COMPANY

  1. 80.

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

    Material

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

GFD40386Courtesy 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.

GFD40387Courtesy of FORD MOTOR COMPANY

  1. 82.

    Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer.

    Use the General Equipment: Strap Wrench

    Torque:

    Stage 1: 103 lb.ft (140 Nm)

    Stage 2: Loosen: 360°

    Stage 3: 74 lb.ft (100 Nm)

    Stage 4: 90°

GFD40388Courtesy of FORD MOTOR COMPANY

  1. 83.

    Install the generator, the bolt and the nut.

    Torque

    : 35 lb.ft (48 Nm)

GFD40639Courtesy of FORD MOTOR COMPANY

  1. 84.

    Install the accessory drive belt tensioner and bolt.

    Torque

    : 35 lb.ft (48 Nm)

GFD40638Courtesy of FORD MOTOR COMPANY

  1. 85.

    Install a new coolant pump O-ring seal and lubricate with clean engine coolant.

    Material

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

GFD40444Courtesy of FORD MOTOR COMPANY

  1. 86.

    Install the coolant pump and bolts.

    Torque:

    Stage 1: 177 lb.in (20 Nm)

    Stage 2: 60°

GFD40637Courtesy of FORD MOTOR COMPANY

  1. 87.

    Install the coolant pump pulley and the bolts.
GFD40636Courtesy of FORD MOTOR COMPANY

  1. 88.

    Install the A/C compressor belt tensioner and the bolt.

    Torque

    : 18 lb.ft (25 Nm)

GFD40635Courtesy of FORD MOTOR COMPANY

  1. 89.

    Rotate the A/C compressor belt tensioner clockwise and install the A/C compressor belt.
GFD40634Courtesy of FORD MOTOR COMPANY

  1. 90.

    Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
GFD40633Courtesy of FORD MOTOR COMPANY

  1. 91.

    Tighten the coolant pump pulley bolts.

    Torque

    : 18 lb.ft (25 Nm)

GFD40632Courtesy of FORD MOTOR COMPANY

  1. 92.

    Install a new thermostat housing O-ring seal.
GFD40708Courtesy of FORD MOTOR COMPANY

  1. 93.

    Install the thermostat housing and bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD40630Courtesy of FORD MOTOR COMPANY

  1. 94.

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

    Using the special tools, install new spark plug tube seals into the LH valve cover.

    Use Special Service Tool: 205-153 (T80T-4000-W)Handle, 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

GFD40565Courtesy of FORD MOTOR COMPANY

  1. 95.

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

    Using the special tools, install new VCT variable force solenoid seals into the LH valve cover.

    Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-142 (T80T-4000-J) installer, Differential Bearing Cone.

GFD40566Courtesy of FORD MOTOR COMPANY

  1. 96.

    Install a new gasket onto the LH valve cover.
GFD40567Courtesy of FORD MOTOR COMPANY

  1. 97.

    NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.

    Material

    : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

GFD40568Courtesy of FORD MOTOR COMPANY

  1. 98.

    Install the LH valve cover and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD40569Courtesy of FORD MOTOR COMPANY

  1. 99.

    1. 1.

      Push the oil level indicator tube into the engine.

    1. 2.

      Rotate the oil level indicator tube clockwise.

    1. 3.

      Verify the tab is locked in place.

    1. 4.

      Install the oil level indicator.
GFD40570Courtesy of FORD MOTOR COMPANY

  1. 100.

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

    Using the special tools, install new spark plug tube seals into the RH valve cover.

    Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

GFD40565Courtesy of FORD MOTOR COMPANY

  1. 101.

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

    Using the special tools, install new VCT variable force solenoid seals into the RH valve cover.

    Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-142 (T80T-4000-J)installer, Differential Bearing Cone.

GFD40566Courtesy of FORD MOTOR COMPANY

  1. 102.

    Install a new gasket onto the RH valve cover.
GFD40577Courtesy of FORD MOTOR COMPANY

  1. 103.

    NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.

    Material

    : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

GFD40578Courtesy of FORD MOTOR COMPANY

  1. 104.

    Install the RH valve cover and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD40579Courtesy of FORD MOTOR COMPANY

  1. 105.

    NOTE: When installing ignition coils, apply a small amount of silicone brake caliper grease and dielectric compound to the inside of the ignition coil boots before installation.

    Install the ignition coils and the bolts.

    Material

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

    Torque:

    Stage 1: 62 lb.in (7 Nm)

    Stage 2: 50°

GFD40627Courtesy of FORD MOTOR COMPANY

  1. 106.

    Install the wiring harness onto the engine and install the nut.

    Torque

    : 89 lb.in (10 Nm)

GFD40626Courtesy of FORD MOTOR COMPANY

  1. 107.

    Connect the KS electrical connectors.
GFD40625Courtesy of FORD MOTOR COMPANY

  1. 108.

    Attach the wiring harness retainer to the engine front cover stud bolt.
GFD40624Courtesy of FORD MOTOR COMPANY

  1. 109.

    1. 1.

      Attach the engine wiring harness retainers.

    1. 2.

      Connect the engine wiring harness electrical connectors.

    1. 3.

      Install the wiring harness insulator.
GFD40709Courtesy of FORD MOTOR COMPANY

  1. 110.

    Connect the engine wiring harness electrical connectors.
GFD40622Courtesy of FORD MOTOR COMPANY

  1. 111.

    Connect the CHT sensor and the CKP sensor electrical connectors.
GFD40621Courtesy of FORD MOTOR COMPANY

  1. 112.

    • Install the RH camshaft position sensors and the bolts.

      Torque

      : 89 lb.in (10 Nm)

    • Connect the RH camshaft position sensor electrical connectors.
    • Attach the wiring harness retainer.
GFD40620Courtesy of FORD MOTOR COMPANY

  1. 113.

    • Attach the wiring harness retainers.
    • Connect the VCT variable force solenoids and ignition coils electrical connectors.
GFD40619Courtesy of FORD MOTOR COMPANY

  1. 114.

    NOTE: 4x2 shown in illustration, 4x4 similar.
    • Attach the wiring harness retainers.
    • Connect the VCT variable force solenoids and ignition coils electrical connectors.
GFD40618Courtesy of FORD MOTOR COMPANY

  1. 115.

    Install new studs and new gasket.

    Torque

    : 18 lb.ft (25 Nm)

GFD40478Courtesy of FORD MOTOR COMPANY

  1. 116.

    Install the exhaust manifold.
    • Install the new nuts.

      Torque:

      Stage 1: 18 lb.ft (24 Nm)

      Stage 2: 24 lb.ft (32 Nm)

GFD40710Courtesy of FORD MOTOR COMPANY

  1. 117.

    Install the heat shield and bolts.

    Torque

    : 106 lb.in (12 Nm)

GFD40616Courtesy of FORD MOTOR COMPANY

  1. 118.

    NOTE: Some replacement exhaust manifolds do not come with studs.

    If necessary, install new studs.

    Torque

    : 30 lb.ft (40 Nm)

GFD40480Courtesy of FORD MOTOR COMPANY

  1. 119.

    Install new studs and new gasket.

    Torque

    : 18 lb.ft (25 Nm)

GFD40711Courtesy of FORD MOTOR COMPANY

  1. 120.

    Install the exhaust manifold.
    • Install the new nuts.

      Torque:

      Stage 1: 18 lb.ft (24 Nm)

      Stage 2: 24 lb.ft (32 Nm)

GFD40712Courtesy of FORD MOTOR COMPANY

  1. 121.

    Install the heat shield and bolts.

    Torque

    : 106 lb.in (12 Nm)

GFD40613Courtesy of FORD MOTOR COMPANY

  1. 122.

    NOTE: Some replacement exhaust manifolds do not come with studs.

    If necessary, install new studs.

    Torque

    : 30 lb.ft (40 Nm)

GFD40495Courtesy of FORD MOTOR COMPANY

  1. 123.

    NOTE: If a new RH engine mount is installed, remove the 2 studs prior to positioning the engine in the vehicle.

    Install the RH engine mount and the new bolts.

    Torque

    : 46 lb.ft (63 Nm)

GFD40466Courtesy of FORD MOTOR COMPANY

  1. 124.

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

    Torque

    : 46 lb.ft (63 Nm)

GFD40454Courtesy of FORD MOTOR COMPANY

  1. 125.

    Install the special tool and remove the engine from the engine stand using a floor crane.

    Install Special Service Tool: 303-F047 Lifting Bracket, Engine.

    Use the General Equipment: Floor Crane

    Use the General Equipment: Mounting Stand

GFD40612Courtesy of FORD MOTOR COMPANY

  1. 126.

    Lubricate the seal bore and the seal lips with clean engine oil.

    Material

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

GFD40392Courtesy of FORD MOTOR COMPANY

  1. 127.

    • 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 onto the tool.
GFD40393Courtesy of FORD MOTOR COMPANY

  1. 128.

    Using the special tools, install the crankshaft rear seal.

    Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 303-1250 Seal Installer, Rear Main.

GFD40394Courtesy of FORD MOTOR COMPANY

  1. 129.

    Install the engine-to-transmission spacer plate and the crankshaft sensor ring.
GFD40611Courtesy of FORD MOTOR COMPANY

  1. 130.

    Install the flexplate and the bolts.

    Torque:

    Stage 1: 177 lb.in (20 Nm)

    Stage 2: 60°

GFD40502Courtesy of FORD MOTOR COMPANY
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