Section 1 (Engine - 1.0L ECOBOOST (92KW/125PS)): Assembly: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-1567 Sizer, Teflon Seal TKIT-2010C-FLM
Courtesy of FORD MOTOR COMPANY	303-1602 Locking Tool, Crankshaft
Courtesy of FORD MOTOR COMPANY	303-1603 Installer, Front Cover Seal
Courtesy of FORD MOTOR COMPANY	303-1604 Timing Peg, Crankshaft TDC
Courtesy of FORD MOTOR COMPANY	303-1605 Alignment Tool, Camshaft
Courtesy of FORD MOTOR COMPANY	303-1606 Locking Tool, Variable Camshaft Timing
Courtesy of FORD MOTOR COMPANY	303-1611 Torque Multiplier
Courtesy of FORD MOTOR COMPANY	303-1611-01 Adapter for 303-1611
Courtesy of FORD MOTOR COMPANY	303-1611-02 Adapter for 303-1611, Torque Multiplier TKIT-2014A-FL TKIT-2014A-ROW
Courtesy of FORD MOTOR COMPANY	310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM
Feeler Gauge
Clutch Alignment Tool
Plastic Scraper
Polydrive Bit Socket
Hose Clamp Remover/Installer
6 mm Drill Bit
Piston Ring Compressor
Punch
4 mm Drill Bit

Materials 

1. Install the engine piston oil cooler valves and the bolts.

   Torque

   : 89 lb.in (10 Nm)

   Courtesy of FORD MOTOR COMPANY

2. • Measure the diameter in two directions.
   • Record the smallest measurement for each crankshaft main bearing journal.

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3. • Using the original bolts, install the main bearing caps and the bolts finger tight.
   • Tighten the bolts in sequence shown.

     Torque

     :Stage 1: 89 lb.in (10 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 22 lb.ft (30 Nm) Stage 4: 15°

   Fig 1: Main Bearing Caps Bolts Tightening Sequence

   Courtesy of FORD MOTOR COMPANY
4. Measure each crankshaft block main bearing bore diameter.

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5. Using the chart, select the crankshaft main bearings.

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6. Using the original bolts, install the connecting rod caps and the bolts.

   Torque

   :Stage 1: 71 lb.in (8 Nm) Stage 2: 106 lb.in (12 Nm) Stage 3: 159 lb.in (18 Nm) Stage 4: 35°

   Courtesy of FORD MOTOR COMPANY

7. • Measure the diameter in two directions.
   • Record the smallest measurement for each connecting rod.

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8. • Remove the bolts and the connecting rod caps.
   • Discard the bolts.

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9. • Measure the diameter in two directions.
   • Record the smallest measurement for each connecting rod journal.

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10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

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11. • Remove the bolts and the main bearing caps.
    • Discard the bolts.

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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.
    NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

    Lubricate with clean engine oil and install crankshaft main bearings.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

13. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

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

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

14. Lubricate with clean engine oil and install the crankshaft.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

15. Install the main bearing caps and the bolts.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Torque

    :Stage 1: 89 lb.in (10 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 22 lb.ft (30 Nm) Stage 4: 15°

    Courtesy of FORD MOTOR COMPANY

16. • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • Acceptable crankshaft end play is 0.220-0.450 mm (0.0087-0.0177 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.

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17. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

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

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

18. NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper side.
    NOTE: Arrows face the front of the engine.
    1. Upper compression ring gap location.
    2. Upper oil control segment ring gap location.
    3. Expander ring gap location.
    4. Lower oil control segment ring gap location.
    5. Lower compression ring gap location.

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19. 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: Make sure the piston arrow on top is facing toward the front of the engine.

    Lubricate with clean engine oil and install the pistons. Use the General Equipment: Piston Ring Compressor

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

20. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Install the connecting rod caps and the bolts.

    Torque

    :Stage 1: 71 lb.in (8 Nm) Stage 2: 106 lb.in (12 Nm) Stage 3: 159 lb.in (18 Nm) Stage 4: 35°

    Fig 2: Connecting Rod Caps Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
21. NOTE: Make sure that the mating faces are clean and free of foreign material.
    NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after installation.
    • Install the crankshaft rear seal and the bolts finger tight.
    • Tighten the bolts in sequence shown.

      Torque

      :Stage 1: 35 lb.in (4 Nm) Stage 2: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

    6-Speed Manual Transmission - B6 

22. NOTE: Make sure that new bolts are installed.
    • Install the flywheel and the bolts finger tight.
    • Install Special Service Tool: 303-1602 Locking Tool, Crankshaft.
    • Tighten the bolts in sequence shown.

      Torque

      :Stage 1: 89 lb.in (10 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 37 lb.ft (50 Nm) Stage 4: 90°

    • Remove Special Service Tool: 303-1602 Locking Tool, Crankshaft.

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    6-Speed Automatic Transmission - 6F15 

23. NOTE: Make sure that new bolts are installed.
    • Install the flexplate and the bolts finger-tight.
    • Install Special Service Tool: 303-1602 Locking Tool, Crankshaft.
    • Tighten the flexplate bolts in sequence shown.

      Torque

      : 37 lb.ft (50 Nm)

    • Remove Special Service Tool: 303-1602 Locking Tool, Crankshaft.

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    6-Speed Automatic Transmission - 6F15/6-Speed Manual Transmission - B6 

24. Remove the engine plug bolt.

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25. Install Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.

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26. NOTE: Only rotate the crankshaft clockwise.

    Using the screwdriver, rotate the crankshaft slowly until the crankshaft stops.

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    6-Speed Automatic Transmission - 6F15 

27. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
28. NOTE: The drill bit must be installed to maintain the balance shaft timing. Do not remove the drill bit until you are instructed to do so.

    Install a 6 mm drill bit through the oil pump housing and into the balance shaft. Use the General Equipment: 6 mm Drill Bit

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29. NOTE: Make sure that new bolts are installed.
    NOTE: Only tighten the bolts finger tight at this stage.

    Install the oil pump and the bolts.

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30. NOTE: Make sure that new bolts are installed.

    Install the remaining bolts and tighten in sequence shown.

    Torque

    :1-3, M8x50: 17 lb.ft (23 Nm)4, M8x65: 17 lb.ft (23 Nm) 5, M8x50: 17 lb.ft (23 Nm) 6-8, M8x65: 17 lb.ft (23 Nm)

    Courtesy of FORD MOTOR COMPANY

31. Install the oil pump belt tensioner and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

32. 1. Lubricate with clean engine oil and install the oil pump drive pulley.

       Material

       : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    2. Using a suitable tool, rotate the oil pump belt tensioner.
    3. Install the oil pump belt.

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33. NOTE: Make sure that the component is installed to the position noted before removal.

    Install the balance shaft weight.

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34. NOTE: Make sure that a new bolt is installed.
    NOTE: Make sure that the component is correctly installed.
    NOTE: Only tighten the bolt finger tight at this stage.

    Install the balance shaft gear and the bolt.

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35. NOTE: Make sure that new bolts are installed.
    NOTE: Install all the bolts finger tight before final tightening.

    Install the oil pump gear and the bolts.

    Torque

    : 26 lb.ft (35 Nm)

    Courtesy of FORD MOTOR COMPANY

36. Tighten the balance shaft gear bolt.

    Torque

    : 26 lb.ft (35 Nm)

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37. Remove the 4 mm drill bit. Remove the General Equipment: 4 mm Drill Bit

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38. NOTE: Make sure that the component is correctly installed.

    Install the oil pump cover.

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    6-Speed Manual Transmission - B6 

39. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
40. Install the oil pan baffle and the bolts.

    Torque

    : 17 lb.ft (23 Nm)

    Courtesy of FORD MOTOR COMPANY

41. Install the oil pump and the bolts.

    Torque

    : 17 lb.ft (23 Nm)

    Courtesy of FORD MOTOR COMPANY

42. NOTE: Make sure that the component is installed to the position noted before removal.

    Install the oil pump drive belt. Lubricate with clean engine oil and install the oil pump drive pulley.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

43. Install the oil pump cover.

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    6-Speed Automatic Transmission - 6F15/6-Speed Manual Transmission - B6 

44. Install the cylinder head gasket.

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45. NOTE: Make sure that no fluids are present in the cylinder head bolt threaded bores.
    1. Install the cylinder head.
    2. NOTE: Make sure that new bolts are installed.
       NOTE: Only tighten the bolts finger tight at this stage.

       Install the cylinder head bolts.

    3. Tighten the cylinder head bolts in sequence shown. Use the General Equipment: Polydrive Bit Socket

       Torque

       :Stage 1: 89 lb.in (10 Nm) Stage 2: 30 lb.ft (40 Nm) Stage 3: Loosen: 45° Stage 4: 22 lb.ft (30 Nm) Stage 5: 90° Stage 6: 90°

    Courtesy of FORD MOTOR COMPANY

46. NOTE: Install the components in their original position.

    Lubricate with clean engine oil and install the valve tappets.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

47. Using the screwdriver, rotate the flywheel in a counterclockwise direction.

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48. NOTE: Make sure that the components are installed to the position noted before removal.
    • Lubricate and install the camshafts approximately at valve overlap position cylinder No. 1.

      Material

      : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    • Lubricate the camshaft journals and camshaft bearing caps with clean engine oil and install.

      Material

      : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    • Install all the original bolts finger tight before final tightening.
    • Tighten 2 turns at a time in the sequence shown in 2 stages.

      Torque

      :Stage 1: 35 lb.in (4 Nm) Stage 2: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

49. • Rotate the camshafts and measure the valve clearances. Note each cylinder number and the valve clearances measured. Use the General Equipment: Feeler Gauge
    • Compare the measured valve clearance(s) with the specifications. Refer to: Specifications  .

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50. NOTE: Note the position of the components before removal.

    Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps and remove the bolts, caps and the camshafts.

    • Discard the bolts.

    Courtesy of FORD MOTOR COMPANY

51. • Remove the valve tappet and read the thickness from the underside.
    • The number on the valve tappet indicates the thickness of the bottom of the tappet. However, the number only indicates the digits after the decimal point (example: 725 = 2.725).

52. • Calculate the required thickness of the valve tappet with the following formula: X = S + M - V
    • Required thickness of tappet = X
    • Thickness of currently fitted tappet = S
    • Measurement of existing valve clearance (actual value) = M
    • Desired valve clearance = V

53. Install the correct valve tappet.
54. NOTE: Make sure that the mating faces are clean and free of foreign material.
    NOTE: The component must be installed within 5 minutes of applying the sealant.

    Apply 3 mm (0.118 in) beads of gasket maker to the intake rear camshaft bearing cap mating surface as shown.

    Material

    : Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

    Courtesy of FORD MOTOR COMPANY

55. NOTE: Make sure that the mating faces are clean and free of foreign material.
    NOTE: The component must be installed within 5 minutes of applying the sealant.

    Apply 3 mm (0.118 in) beads of gasket maker to the intake rear camshaft bearing cap mating surface as shown.

    Material

    : Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

    Courtesy of FORD MOTOR COMPANY

56. NOTE: Make sure that the components are installed to the position noted before removal.
    1. Lubricate and install the camshafts approximately at valve overlap position cylinder No. 1.

       Material

       : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    2. Lubricate the camshaft journals and camshaft bearing caps with clean engine oil and install.

       Material

       : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    3. Install all the new bolts finger tight before final tightening.
    4. Tighten 2 turns at a time in the sequence shown in 2 stages.

       Torque

       :Stage 1: 35 lb.in (4 Nm) Stage 2: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

57. 1. Install Special Service Tool: 303-1605 Alignment Tool, Camshaft.
    2. NOTE: Only tighten the bolts finger tight at this stage.
    3. Torque

       : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

58. Install the VCT units.

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59. Install Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.

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60. NOTE: Only tighten the bolts finger tight at this stage.

    Install the VCT units mounting bolt.

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61. Remove Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.

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62. Install the thermostat and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

63. NOTE: Make sure that the component is installed to the position noted before removal.
    • Lubricate with clean engine oil and install the timing drive pulley.

      Material

      : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    • Install the oil supply filter and the bolt.

      Torque

      : 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

64. WARNING: The tensioner is under spring tension. Be careful when handling the tensioner. Failure to follow this instruction may result in personal injury.

    Install the timing belt tensioner.

    Torque

    : 19 lb.ft (26 Nm)

    Courtesy of FORD MOTOR COMPANY

65. Install the timing belt in sequence shown.

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66. WARNING: Take extra care when handling the compressed spring.

    Remove the locking pin.

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67. 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 scraping tool to remove traces of sealant.
    NOTE: Make sure that the mating faces are clean and free of foreign material.
    1. Clean only the specified area with the specified material and a plastic scraping tool to remove traces of sealant. Use the General Equipment: Plastic Scraper
    2. Make sure that the surface is clean and free of foreign material before taping around the component.

       Material

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

    Courtesy of FORD MOTOR COMPANY

68. Install a new gasket.

    Courtesy of FORD MOTOR COMPANY

69. NOTE: The component must be installed within 10 minutes of applying the sealant.

    Apply beads of silicone sealant that are 4 mm (0.157 in) and 6 mm (0.236 in) as shown in the graphic.

    Material

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

    Courtesy of FORD MOTOR COMPANY

70. NOTE: The component must be installed within 10 minutes of applying the sealant.

    Apply beads of silicone sealant that are 4 mm (0.157 in) and 6 mm (0.236 in) as shown in the graphic.

    Material

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

    Courtesy of FORD MOTOR COMPANY

71. Install the engine front cover, bolts and tighten in the sequence shown.
    1. NOTE: Make sure that new components are installed.

       Torque

       :1-2, M6x60: 44 lb.in (5 Nm)

    2. NOTE: Make sure that new components are installed.

       Torque

       :3-6, M10x95: 89 lb.in (10 Nm)

    3. NOTE: Make sure that new components are installed.

       Torque

       :7-16 M6x60: 44 lb.in (5 Nm)

    4. Torque

       :17-19 M6x60: 44 lb.in (5 Nm)20 M6x75: 44 lb.in (5 Nm)

    5. Torque

       :3-6: 30 lb.ft (40 Nm)

    6. Torque

       :3-4:Stage 1: 52 lb.ft (70 Nm) Stage 2: 90°

    7. Torque

       :5-6:Stage 1: 52 lb.ft (70 Nm) Stage 2: 90°

    8. 1-2

       Torque

       :Stage 1: 80 lb.in (9 Nm) Stage 2: 90°

    9. 7-20

       Torque

       :Stage 1: 133 lb.in (15 Nm) Stage 2: 90°

    Courtesy of FORD MOTOR COMPANY

72. Tighten the RH engine mount studs.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

73. Install the CKP sensor and the bolt.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

74. NOTE: Make sure that a new component is installed.

    Using the special tool, install the crankshaft front seal. Use Special Service Tool: 303-1603 Installer, Front Cover Seal.

    Courtesy of FORD MOTOR COMPANY

75. Install Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

76. 1. Turn until resistance is felt.
    2. Torque

       : 133 lb.in (15 Nm)

    Courtesy of FORD MOTOR COMPANY

77. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Tighten the VCT units bolt.

    Torque

    : 22 lb.ft (30 Nm)

    Courtesy of FORD MOTOR COMPANY

78. Remove Special Service Tool: 303-1605 Alignment Tool, Camshaft.

    Courtesy of FORD MOTOR COMPANY

79. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Tighten the VCT units bolt.

    Torque

    :Stage 1: 37 lb.ft (50 Nm) Stage 2: 70 lb.ft (95 Nm) Stage 3: 45°

    Courtesy of FORD MOTOR COMPANY

80. NOTE: Only rotate the crankshaft clockwise.

    Rotate the crankshaft slowly until the crankshaft stops.

    Courtesy of FORD MOTOR COMPANY

81. 1. NOTE: The production engine is not equipped with a friction washer. Whenever the crankshaft pulley is removed, a friction washer (base part number 6378) must be installed.

       Install a new friction washer.

    2. Install the crankshaft pulley.
    3. Install a new crankshaft pulley bolt finger tight.

    Courtesy of FORD MOTOR COMPANY

82. 1. Install 3/16 inch punch. Use the General Equipment: Punch
    2. Tighten the crankshaft pulley bolt.

       Torque

       :Stage 1: 18 lb.ft (25 Nm) Stage 2: 52 lb.ft (70 Nm)

    Courtesy of FORD MOTOR COMPANY

83. Remove 3/16 inch punch. Use the General Equipment: Punch

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84. 1. M8x30
    2. M8x25Install Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier.

       Torque

       : 18 lb.ft (24 Nm)

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85. Install Special Service Tool: 303-1611-01 Adapter for 303-1611.

    Torque

    : 18 lb.ft (24 Nm)

    Courtesy of FORD MOTOR COMPANY

86. 1. Install Special Service Tool: 303-1611 Torque Multiplier.
    2. Only tighten the nut finger tight at this stage.

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87. 1. Tighten the crankshaft pulley bolt.

       Torque

       : 44 lb.ft (60 Nm)

    2. Torque

       :Stage 1: 90° Stage 2: 90° Stage 3: 90° Stage 4: 90° Stage 5: 90°

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88. Remove Special Service Tool: 303-1611 Torque Multiplier.

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89. • Install 3/16 inch punch. Use the General Equipment: Punch
    • Remove 3/16 inch punch. Use the General Equipment: Punch

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90. Remove Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.

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91. Remove Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.

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    6-Speed Automatic Transmission - 6F15 

92. Remove the 6 mm drill bit. Remove the General Equipment: 6 mm Drill Bit

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    6-Speed Automatic Transmission - 6F15/6-Speed Manual Transmission - B6 

93. NOTE: Only rotate the crankshaft clockwise.

    Rotate the crankshaft 1 and 3/4 revolutions and continue until piston No. 1 is approximately 45° before top dead center (BTDC).

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94. Install Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.

    Courtesy of FORD MOTOR COMPANY

95. NOTE: Only rotate the crankshaft clockwise.

    Rotate the crankshaft slowly until the crankshaft stops.

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96. 1. NOTE: The punch can only be installed if the valve timing is correct.

       Install 3/16 inch punch. Use the General Equipment: Punch

    2. Remove 3/16 inch punch. Use the General Equipment: Punch

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97. Remove Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.

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98. Install the engine plug bolt.

    Torque

    : 177 lb.in (20 Nm)

    Courtesy of FORD MOTOR COMPANY

99. Remove Special Service Tool: 303-1611-01 Adapter for 303-1611.

    Courtesy of FORD MOTOR COMPANY

100. Remove Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier.

     Courtesy of FORD MOTOR COMPANY

101. 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 scraping tool to remove traces of sealant.
     1. Clean only the specified area with the specified material and a plastic scraping tool to remove traces of sealant. Use the General Equipment: Plastic Scraper
     2. Make sure that the surface is clean and free of foreign material before taping around the component.

        Material

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

     Courtesy of FORD MOTOR COMPANY

102. NOTE: The component must be installed within 5 minutes of applying the sealant.

     Apply a 3.5 mm (0.137 in) bead of silicone sealant.

     Material

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

     Courtesy of FORD MOTOR COMPANY

103. • Install the oil pan and the bolts finger tight.
     • Tighten the oil pan bolts in sequence shown.

       Torque

       :1-15: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

104. NOTE: Make sure that the component is clean, free of foreign material and lubricant.
     1. Apply a 5 mm (0.196 in) bead of silicone sealant.

        Material

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

     2. Apply a 4 mm (0.157 in) bead of gasket maker.

        Material

        : Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

     Courtesy of FORD MOTOR COMPANY

105. Install the valve cover gasket.

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106. • NOTE: Only tighten the bolts finger tight at this stage.

       Install the valve cover, studs and the bolts.

     • Install the oil level indicator.

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107. Tighten the valve cover studs and bolts in sequence shown.

     Torque

     : 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

108. Install the engine lifting bracket and the bolts.

     Torque

     : 17 lb.ft (23 Nm)

     Courtesy of FORD MOTOR COMPANY

109. Lubricate the seal with clean engine oil, install the VCT solenoids and the retainers.

     Material

     : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     Courtesy of FORD MOTOR COMPANY

110. 1. Install the oil pump control solenoid and the retainer.

        Torque

        : 89 lb.in (10 Nm)

     2. NOTE: Make sure that the components are installed to the position noted before removal.

        Install the KS and the bolt.

        Torque

        : 177 lb.in (20 Nm)

     3. Install the oil pressure switch.

        Torque

        :Stage 1: 44 lb.in (5 Nm) Stage 2: 177 lb.in (20 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Install the oil cooler and the bolt.

     Torque

     : 41 lb.ft (55 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Install the intake manifold, studs and the bolts finger tight.

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113. Tighten the intake manifold studs and the bolts in sequence shown.

     Torque

     : 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

114. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
     1. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
     2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
        NOTE: Make sure that new lower fuel injector Teflon® seals are installed.
     3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

     Courtesy of FORD MOTOR COMPANY

115. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
     NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
     1. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
     2. Position the Teflon® seal sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® seal sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
     3. Once the Teflon® seal sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® seal sizer tool. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.

     Courtesy of FORD MOTOR COMPANY

116. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
     NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

     Material

     : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     Courtesy of FORD MOTOR COMPANY

117. Install the fuel injectors.

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118. • NOTE: Only use moderate force.

       Install the fuel rail and the bolts finger tight.

     • Tighten the bolts 1 turn at a time in sequence shown.

       Torque

       : 17 lb.ft (23 Nm)

     Fig 3: Fuel Rail Bolts Tightening Sequence

     Courtesy of FORD MOTOR COMPANY
119. • Install the intake and exhaust CMP sensor and the retainers.

       Torque

       : 89 lb.in (10 Nm)

     • Install the wire harness and connect the fuel injector electrical connectors and attach the retainers.

     Courtesy of FORD MOTOR COMPANY

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

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

     Courtesy of FORD MOTOR COMPANY

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

     Material

     : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     Courtesy of FORD MOTOR COMPANY

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

     Material

     : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     Courtesy of FORD MOTOR COMPANY

123. Install the high-pressure fuel pump and loosely install the 2 high-pressure fuel pump bolts, alternately tighten each bolt one half of a revolution until seated.

     Torque

     :Stage 1: 44 lb.in (5 Nm) Stage 2: 115 lb.in (13 Nm)

     Courtesy of FORD MOTOR COMPANY

124. NOTE: Make sure that a new component is installed.
     NOTE: Tighten both fittings finger tight prior to final tightening.

     Install the fuel pipe and the nuts.

     Torque

     :Stage 1: 124 lb.in (14 Nm) Stage 2: 177 lb.in (20 Nm) Stage 3: 20°

     Courtesy of FORD MOTOR COMPANY

125. NOTE: Install all the bolts finger tight before final tightening.

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

     Torque

     : 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

126. Install vacuum pump and the stud bolts.

     Torque

     : 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

127. • Position the vacuum harness and attach the retainers.
     • Install the vacuum solenoid and the nuts.

       Torque

       : 89 lb.in (10 Nm)

     • Connect the vacuum harness quick connector.
     • Connect the vacuum hose and clamp.

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128. Connect the PCV tube coupling.

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129. • Install the coolant hose assembly and the bolts.

       Torque

       : 89 lb.in (10 Nm)

     • Connect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
     • Attach the coolant hose to the retainers.

     Courtesy of FORD MOTOR COMPANY

130. Install the turbocharger mounting studs.

     Torque

     : 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

131. Install the heat shield and the bolt.

     Torque

     : 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

132. Install the turbocharger gasket.

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133. Install the turbocharger oil supply tube and the retainers.

     Torque

     : 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

134. Install the new turbocharger oil drain tube gasket is installed.

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135. Install the turbocharger oil drain tube and the retainers.

     Courtesy of FORD MOTOR COMPANY

136. • NOTE: Only tighten the nuts and retainers finger tight at this stage.

       Install the turbocharger assembly and the nuts.

     • Connect the vacuum hose. Use the General Equipment: Hose Clamp Remover/Installer
     • Install the turbocharger oil drain tube retainer finger tight.

     Courtesy of FORD MOTOR COMPANY

137. • Tighten the turbocharger assembly mounting nuts in sequence shown.

       Torque

       :1-4:Stage 1: 35 lb.in (4 Nm) Stage 2: 168 lb.in (19 Nm) Stage 3: 17 lb.ft (23 Nm)

     • Tighten the turbocharger oil drain tube retainer.

       Torque

       :5: 89 lb.in (10 Nm)

     • Tighten the turbocharger oil drain tube banjo bolt.

       Torque

       :6: 22 lb.ft (30 Nm)

     Fig 4: Turbocharger Nut Tightening Sequence

     Courtesy of FORD MOTOR COMPANY
138. Install the coolant hose assembly, clamps and the bolts. Use the General Equipment: Hose Clamp Remover/Installer

     Torque

     : 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

139. Install the accessory drive belt idler pulley and the bolt.

     Torque

     : 18 lb.ft (25 Nm)

     Courtesy of FORD MOTOR COMPANY

140. Install the generator and the bolts.

     Torque

     : 35 lb.ft (48 Nm)

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141. WARNING: Take extra care when handling the compressed spring.

     Install the accessory drive belt tensioner and the bolts. Use the General Equipment: 4 mm Drill Bit

     Torque

     : 18 lb.ft (25 Nm)

     Courtesy of FORD MOTOR COMPANY

142. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

     Courtesy of FORD MOTOR COMPANY

     Courtesy of FORD MOTOR COMPANY

     6-Speed Manual Transmission - B6 

143. 1. Install the clutch disc and pressure plate on the flywheel. Center the clutch disc to the crankshaft with a clutch alignment tool. Tighten every other pressure plate bolt 2 turns at a time. Use the General Equipment: Clutch Alignment Tool

        Torque

        : 16 lb.ft (22 Nm)

     2. Torque

        : 21 lb.ft (29 Nm)

Courtesy of FORD MOTOR COMPANY