Cylinder Head: Installation

All cylinder heads 

1. Verify the crankshaft keyway is in the 9 o'clock position.
   Fig 1: Locating Crankshaft Keyway In 9 O'Clock Position

   Courtesy of FORD MOTOR CO.
NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in future oil leakage.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown in illustration, RH similar.
Fig 2: Identifying Cylinder Head Alignment Pins
Courtesy of FORD MOTOR CO.
2. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.

   RH cylinder head 

3. Tighten the new RH cylinder head bolts in 4 stages in the sequence shown in illustration.
   • Stage 1: Tighten to 25 Nm (18 lb-ft).
   • Stage 2: Tighten to 40 Nm (30 lb-ft).
   • Stage 3: Tighten an additional 90 degrees.
   • Stage 4: Tighten an additional 90 degrees.
     Fig 3: Identifying RH Cylinder Head Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraper to clean the sealing surfaces.
4. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
5. Install 8 new RH exhaust manifold studs.
   • Tighten to 25 Nm (18 lb-ft).
     Fig 4: Locating RH Exhaust Manifold Studs

     Courtesy of FORD MOTOR CO.
6. Install a new gasket, the RH exhaust manifold and 8 new nuts.
   • Tighten the nuts in the sequence shown in illustration in 2 stages.
     • Stage 1: Tighten to 24 Nm (18 lb-ft).
     • Stage 2: Tighten to 32 Nm (24 lb-ft).
       Fig 5: Identifying RH Exhaust Manifold Nuts Tightening Sequence

       Courtesy of FORD MOTOR CO.
7. Install the RH exhaust manifold heat shield and the 3 bolts.
   • Tighten to 12 Nm (106 lb-in).
     Fig 6: Locating Bolts And RH Exhaust Manifold Heat Shield

     Courtesy of FORD MOTOR CO.
8. Install the Cylinder Head Temperature (CHT) sensor.
   • Tighten to 11 Nm (97 lb-in).
     Fig 7: Locating CHT Sensor

     Courtesy of FORD MOTOR CO.
9. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
   Fig 8: Locating Cylinder Head Temperature Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
10. Install the heat shield, the bolt and the stud bolt on the RH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
      Fig 9: Locating Bolt, Stud Bolt And Heat Shield On RH Cylinder Head

      Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine coolant prior to installing.
11. Using a new O-ring seal, install the coolant outlet pipe.
    • Tighten to 10 Nm (89 lb-in).
      Fig 10: Locating Bolt And Coolant Outlet Pipe On Cylinder Head

      Courtesy of FORD MOTOR CO.

    LH cylinder head 

12. Tighten the new LH cylinder head bolts in 4 stages in the sequence shown in illustration.
    • Stage 1: Tighten to 25 Nm (18 lb-ft).
    • Stage 2: Tighten to 40 Nm (30 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
    • Stage 4: Tighten an additional 90 degrees.
      Fig 11: Identifying LH Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraper to clean the sealing surfaces.
13. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
14. Install 8 new LH exhaust manifold studs.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 12: Locating LH Exhaust Manifold Studs

      Courtesy of FORD MOTOR CO.
15. Install a new gasket, the LH exhaust manifold and 8 new nuts.
    • Tighten in the sequence shown in illustration in 2 stages.
      • Stage 1: Tighten to 24 Nm (18 lb-ft).
      • Stage 2: Tighten to 32 Nm (24 lb-ft).
        Fig 13: Identifying LH Exhaust Manifold Nuts Tightening Sequence

        Courtesy of FORD MOTOR CO.
16. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 14: Locating Bolts And LH Exhaust Manifold Heat Shield

      Courtesy of FORD MOTOR CO.
17. Attach the wiring harness retainer to the LH cylinder head.
    Fig 15: Locating Wiring Harness Retainer At LH Cylinder Head

    Courtesy of FORD MOTOR CO.
18. Install the heat shield and the 2 bolts to the LH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
      Fig 16: Locating Bolts And Heat Shield On LH Cylinder Head

      Courtesy of FORD MOTOR CO.
19. Using a new gasket, install the coolant outlet and 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 17: Locating Bolts And Coolant Outlet On Cylinder Head

      Courtesy of FORD MOTOR CO.
NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.
Fig 18: Locating Camshaft Roller Follower And Hydraulic Lash Adjuster Assemblies
Courtesy of FORD MOTOR CO.
20. Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
NOTE: Lubricate the camshafts with clean engine oil prior to installation.
Fig 19: Locating LH Intake And Exhaust Camshafts D-Slots
Courtesy of FORD MOTOR CO.
21. Install the LH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.
22. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
23. Install the LH front camshaft bearing mega cap and the 4 bolts. Do not tighten the bolts at this time
    Fig 20: Locating Bolts And LH Front Camshaft Bearing Mega Cap

    Courtesy of FORD MOTOR CO.
24. Tighten the bolts in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
      Fig 21: Identifying Camshaft Bearing Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Intake camshaft shown in illustration, exhaust camshaft similar.
Fig 22: Installing VCT System Oil Filter In Intake And Exhaust Camshafts
Courtesy of FORD MOTOR CO.
25. Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.
26. Install the secondary timing chain onto the LH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
    1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
    2. The timing mark on the exhaust VCT assembly should align with the single colored link.
       Fig 23: Aligning Colored Links On Secondary Timing Chain With Timing Marks On VCT Assemblies

       Courtesy of FORD MOTOR CO.
27. Install the LH VCT assemblies and the secondary timing chain onto the LH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 11 o'clock position.
    Fig 24: Locating Timing Mark On Exhaust VCT Assembly In 11 O'Clock Position

    Courtesy of FORD MOTOR CO.
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.
28. 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.
      Fig 25: Locating Secondary Timing Chain Centered Over Tensioner

      Courtesy of FORD MOTOR CO.
NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.
29. Install the 3 LH intake VCT assembly bolts and the 3 LH exhaust VCT assembly bolts.
    • Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.
      Fig 26: Locating LH Intake Variable Camshaft Timing Assembly Bolts And LH Exhaust VCT Assembly Bolts

      Courtesy of FORD MOTOR CO.
30. Install the LH primary timing chain.
    • Align the colored link on the timing chain with the timing mark on the LH VCT assembly.
      Fig 27: Aligning Colored Link On Timing Chain With Timing Mark On LH VCT Assembly

      Courtesy of FORD MOTOR CO.
31. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
    Fig 28: Aligning Remaining Colored Link On Timing Chain With Timing Mark On Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
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 9 o'clock position after installing the LH timing chain guide.
32. Install the LH timing chain guide and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 29: Locating Bolt And LH Timing Chain Guide

      Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain tensioner arm.
Fig 30: Locating LH Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
NOTE: Complete the following 3 steps on both the LH and RH primary timing chain tensioners.
33. Install the LH timing chain tensioner arm.
NOTE: Do not compress the ratchet assembly or damage to the tensioner will occur.
Fig 31: Compressing Primary Timing Chain Tensioner Plunger, Using An Edge Of Vise
Courtesy of FORD MOTOR CO.
34. Compress the primary timing chain tensioner plunger, using an edge of a vise.
35. Using a small screwdriver or pick, push back and hold the ratchet mechanism, then push the ratchet arm back into the tensioner housing.
    Fig 32: Pushing Ratchet Arm Back Into Tensioner Housing Using Small Screwdriver Or Pick

    Courtesy of FORD MOTOR CO.
36. Install a suitable pin into the hole of the tensioner housing to hold the ratchet assembly and plunger in place during installation.
    Fig 33: Installing Suitable Pin Into Hole Of Tensioner Housing To Hold Ratchet Assembly And Plunger

    Courtesy of FORD MOTOR CO.
37. Install the LH primary timing chain tensioner and 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Remove the holding pin from the tensioner.
      Fig 34: Locating LH Primary Timing Chain Tensioner, Bolts And Holding Pin

      Courtesy of FORD MOTOR CO.
38. Using the crankshaft holding tool, rotate the crankshaft clockwise until the crankshaft keyway is at the 12 o'clock position.
    Fig 35: Rotating Crankshaft Clockwise Until Crankshaft Keyway Is At 12 O'Clock Position Using Crankshaft Holding Tool

    Courtesy of FORD MOTOR CO.
39. With the crankshaft keyway at the 12 o'clock position, verify the timing mark alignment is correct.
    Fig 36: Locating Crankshaft Keyway At 12 O'Clock Position

    Courtesy of FORD MOTOR CO.

    RH cylinder head 

NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.
Fig 37: Locating Camshaft Roller Follower And Hydraulic Lash Adjuster Assemblies
Courtesy of FORD MOTOR CO.
40. Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
NOTE: Lubricate the camshafts with clean engine oil prior to installation.
Fig 38: Locating RH Intake And Exhaust Camshafts D-Slots
Courtesy of FORD MOTOR CO.
41. Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.
42. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
    Fig 39: Locating Bolts And Camshaft Bearing Caps

    Courtesy of FORD MOTOR CO.
43. Install the RH front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time
    Fig 40: Locating Bolts And RH Front Camshaft Bearing Mega Cap

    Courtesy of FORD MOTOR CO.
44. Tighten the bolts in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
      Fig 41: Identifying Camshaft Bearing Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Intake camshaft shown in illustration, exhaust camshaft similar.
Fig 42: Installing VCT System Oil Filter In Intake And Exhaust Camshafts
Courtesy of FORD MOTOR CO.
45. Install the VCT system oil filter in the intake and exhaust camshafts.
46. Install the secondary timing chain onto the RH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
    1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
    2. The timing mark on the exhaust VCT assembly should align with the single colored link.
       Fig 43: Aligning Colored Links On Secondary Timing Chain With Timing Marks On VCT Assemblies

       Courtesy of FORD MOTOR CO.
47. Install the RH VCT assemblies and the secondary timing chain onto the RH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 1 o'clock position.
    Fig 44: Locating Timing Mark On Exhaust VCT Assembly In 1 O'Clock Position

    Courtesy of FORD MOTOR CO.
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.
48. 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.
      Fig 45: Locating Secondary Timing Chain Centered Over Tensioner

      Courtesy of FORD MOTOR CO.
NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.
49. Install the 3 RH intake VCT assembly bolts and the 3 RH exhaust VCT assembly bolts.
    • Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.
      Fig 46: Locating RH Intake Variable Camshaft Timing Assembly Bolts And RH Exhaust VCT Assembly Bolts

      Courtesy of FORD MOTOR CO.

    All cylinder heads 

50. Install the RH primary timing chain.
    • Align the colored link on the timing chain with the timing mark on the RH VCT assembly.
      Fig 47: Aligning Colored Link On Timing Chain With Timing Mark On RH VCT Assembly

      Courtesy of FORD MOTOR CO.
51. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
    Fig 48: Aligning Remaining Colored Link On Timing Chain With Timing Mark On Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
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 12 o'clock position after installing the RH timing chain guide.
52. Install the RH timing chain guide and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 49: Locating Bolt And RH Timing Chain Guide

      Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain tensioner arm.
Fig 50: Locating RH Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
53. Install the RH timing chain tensioner arm.
54. Install the RH primary timing chain tensioner and 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Remove the holding pin from the tensioner.
      Fig 51: Locating RH Primary Timing Chain Tensioner, Bolts And Holding Pin

      Courtesy of FORD MOTOR CO.
55. With the crankshaft keyway still at the 12 o'clock position, verify the timing mark alignment is correct.
    Fig 52: Locating Crankshaft Keyway At 12 O'Clock Position

    Courtesy of FORD MOTOR CO.
NOTE: The Variable Camshaft Timing (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: LH shown in illustration, RH similar.
Fig 53: Locating VCT Variable Force Solenoid Pins
Courtesy of FORD MOTOR CO.
56. Fully depress the VCT variable force solenoid pins.
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. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 54: Applying Bead Of Silicone Gasket And Sealant To Cylinder Head-To-Cylinder Block Joints And Oil Pan-To-Cylinder Block Joints
Courtesy of FORD MOTOR CO.
57. Apply a bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
58. Using new gaskets, position the engine front cover onto the dowels.
    • Install the 13 engine front cover bolts, 2 stud bolts, 2 oil pan-to-engine front cover bolts and 2 oil pan-to-engine front cover stud bolts finger-tight.
      Fig 55: Installing Engine Front Cover On Dowels

      Courtesy of FORD MOTOR CO.
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. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
59. Tighten the bolts in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in).
    • Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.
      Fig 56: Identifying Engine Front Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
60. Using a 10 mm Hex Bit, rotate the engine front cover jackscrew into contact with the oil filter adapter to 5 Nm (44 lb-in).
    Fig 57: Rotating Engine Front Cover Jackscrew Into Contact With Oil Filter Adapter To 5 nm (44 lb-in) Using 10 mm Hex Bit

    Courtesy of FORD MOTOR CO.
61. Install the engine front cover-to-oil filter adapter bolt and tighten to 25 Nm (18 lb-ft) plus an additional 60 degrees.
    Fig 58: Locating Engine Front Cover-To-Oil Filter Adapter Bolt

    Courtesy of FORD MOTOR CO.
62. Position the wiring harness and install the wiring harness retainer to the oil pan stud bolt.
    Fig 59: Locating Wiring Harness Retainer On Oil Pan Stud Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.
Fig 60: Installing Crankshaft Front Oil Seal Using Front Crank Seal And Damper Installer And Front Cover Oil Seal Installer (Plate Only)
Courtesy of FORD MOTOR CO.
63. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft front oil seal.
NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Fig 61: Locating Woodruff Key Slot In Crankshaft Pulley
Courtesy of FORD MOTOR CO.
64. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
65. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
    Fig 62: Locating Crankshaft Pulley Sealing Surface

    Courtesy of FORD MOTOR CO.
66. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft pulley.
    Fig 63: Installing Crankshaft Pulley Using Front Crank Seal And Damper Installer And Front Cover Oil Seal Installer (Plate Only)

    Courtesy of FORD MOTOR CO.
67. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
    • Stage 1: Tighten to 140 Nm (103 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 100 Nm (74 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
      Fig 64: Locating Crankshaft Pulley Bolt And Strap Wrench

      Courtesy of FORD MOTOR CO.
68. Install the generator and the 2 bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 65: Locating Generator Bolts

      Courtesy of FORD MOTOR CO.
69. Connect the wiring harness connector to the generator.
    • Install the B+ wire and nut onto the generator.
      • Tighten to 17 Nm (150 lb-in).
        Fig 66: Locating B+ Wire And Nut On Generator And Wiring Harness Connector

        Courtesy of FORD MOTOR CO.
70. Install the ground wire and nut to the engine front cover stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 67: Locating Nut And Ground Wire At Engine Front Cover Stud Bolt

      Courtesy of FORD MOTOR CO.
71. Attach the wiring harness retainer to the engine front cover stud bolt.
    Fig 68: Locating Wiring Harness Retainer At Engine Front Cover Stud Bolt

    Courtesy of FORD MOTOR CO.
72. Install the accessory drive belt tensioner and the bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 69: Locating Bolt And Accessory Drive Belt Tensioner

      Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new coolant pump O-ring seal with clean engine coolant.
73. Using a new O-ring seal, install the coolant pump and the 4 bolts.
    • Tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.
      Fig 70: Locating Bolts And Coolant Pump

      Courtesy of FORD MOTOR CO.
74. Install the coolant pump pulley and the 4 bolts.
    Fig 71: Locating Bolts And Coolant Pump Pulley

    Courtesy of FORD MOTOR CO.
75. Rotate the A/C compressor belt tensioner clockwise and install the A/C compressor belt.
    Fig 72: Rotating A/C Compressor Belt Tensioner Clockwise

    Courtesy of FORD MOTOR CO.
76. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
    Fig 73: Identifying Accessory Drive Belt Tensioner And Accessory Drive Belt

    Courtesy of FORD MOTOR CO.
77. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).
    Fig 74: Locating Coolant Pump Pulley Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new thermostat housing O-ring seal with clean engine coolant.
78. Using a new thermostat housing O-ring seal, install the thermostat housing and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 75: Locating Bolts And Thermostat Housing

      Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.
Fig 76: Installing Spark Plug Tube Seal Using VCT Spark Plug Tube Seal Installer And Handle
Courtesy of FORD MOTOR CO.
79. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
NOTE: Installation of new seals is only required if damaged seals were removed.
Fig 77: Installing VCT Variable Force Solenoid Seal Using Differential Bearing Cone Installer And Handle
Courtesy of FORD MOTOR CO.
80. Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal(s).
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. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Fig 78: Applying 8 mm (0.31 in) Bead Of Silicone Gasket And Sealant To Engine Front Cover-To-LH Cylinder Head Joints
Courtesy of FORD MOTOR CO.
81. Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.
82. Position the LH valve cover and new gasket on the cylinder head.
    • Tighten the fasteners in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 79: Identifying LH Valve Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
83. Install the oil level indicator.
84. If removed, install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Connect the LH intake and exhaust CMP sensor electrical connectors.
      Fig 80: Locating Bolts, LH Intake And Exhaust CMP Sensors And Electrical Connectors

      Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.
Fig 81: Installing Spark Plug Tube Seal Using VCT Spark Plug Tube Seal Installer And Handle
Courtesy of FORD MOTOR CO.
85. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
NOTE: Installation of new seals is only required if damaged seals were removed.
Fig 82: Installing VCT Variable Force Solenoid Seal Using Differential Bearing Cone Installer And Handle
Courtesy of FORD MOTOR CO.
86. Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal(s).
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. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Fig 83: Applying 8 mm (0.31 in) Bead Of Silicone Gasket And Sealant To Engine Front Cover-To-RH Cylinder Head Joints
Courtesy of FORD MOTOR CO.
87. Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.
88. Position the RH valve cover and new gasket on the cylinder head.
    • Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 84: Identifying RH Valve Cover Fasteners Tightening Sequence

      Courtesy of FORD MOTOR CO.
89. If removed, install the RH intake and exhaust CMP sensors and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Connect the RH intake and exhaust CMP sensor electrical connectors.
      Fig 85: Locating Bolts, RH Intake And Exhaust CMP Sensors And Connectors

      Courtesy of FORD MOTOR CO.
90. Connect the 2 VCT variable force solenoid electrical connectors.
    • Attach the 10 wiring harness retainers to the LH valve cover.
      Fig 86: Locating VCT Variable Force Solenoid Electrical Connectors And Wiring Harness Retainers

      Courtesy of FORD MOTOR CO.
91. Connect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
    • Attach the 10 wiring harness retainers to the RH valve cover.
      Fig 87: Locating VCT Variable Force Solenoid Electrical Connectors And Wiring Harness Retainers

      Courtesy of FORD MOTOR CO.
92. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
    • To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
      Fig 88: Inspecting Coil Seals For Rips, Nicks Or Tears

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs. RH shown in illustration, LH similar.
93. Install the 8 ignition coils and 8 bolts.
    • Tighten to 6 Nm (53 lb-in).
      Fig 89: Locating Ignition Coils And Bolts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 90: Locating Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
94. Connect the 8 ignition coil electrical connectors.
95. Install the engine. For additional information, refer to ENGINE  .