Engine Block Skirt Stiffener

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar, TKIT-2006UF-FLM, TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer, TKIT-2006UF-FLM, TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1250 Seal Installer, Rear Main, TKIT-2006UFFLM
Courtesy of FORD MOTOR COMPANY	303-1531 Installer, Front Crank Seal and Damper
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2), TKIT-2014D-FL_ROW, TKIT-2014D-ROW3
Courtesy of FORD MOTOR COMPANY	303-335 (T88T-6701-A) Installer, Front Cover Oil Seal, TKIT-1988-F, TKIT-1988-FLM
Floor Crane
Mounting Stand
Flat-Bladed Screwdriver
Vise
Vise Jaw Protectors

Materials 

1. NOTE: If the engine block skirt stiffener is not installed, aligned and the bolts tightened to minimum specification within 10 minutes, the sealant must be removed and the sealing area cleaned.

   Apply a 4. 5 mm (0. 18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine block skirt stiffener.

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

   Courtesy of FORD MOTOR COMPANY

2. 1. Position the oil seal.
   2. Install the engine block skirt stiffener.

   Courtesy of FORD MOTOR COMPANY

3. 1. Install the bolts finger tight.
   2. Tighten the 2 bolts.

      Torque:

      Stage 1: 35 lb. in (4 Nm)

      Stage 2: Loosen: 360 °

   Courtesy of FORD MOTOR COMPANY

4. 1. Using a straight edge, align the rear face of the engine block skirt stiffener to the rear face of the engine block, flush or up to 0. 250 mm (0. 01 in) underflush.
   2. Using a straight edge, align the machined bosses on the left side of the engine block skirt stiffener to the machined bosses on the left side of the engine block flush or within 0. 280 mm (0. 011) of flush.

   Courtesy of FORD MOTOR COMPANY

5. NOTE: If the engine block skirt stiffener bolts minimal torque is not completed within 10 minutes of sealant application, or if final torque is not met within 60 minutes of sealant application the parts must be removed and the sealant must be removed and the sealing area cleaned.

   Tighten the engine block skirt stiffener bolts.

   Torque:

   Stage 1: 35 lb. in (4 Nm)

   Stage 2: 18 lb. ft (24 Nm)

   Fig 1: Engine Block Skirt Stiffener Tightening Sequence

   Courtesy of FORD MOTOR COMPANY
6. Install the oil pump and the bolts.

   Torque:

   Stage 1: 89 lb. in (10 Nm)

   Stage 2: 45 °

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7. Install the oil pump drive chain.

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8. Install the oil pump drive chain guide and bolts.

   Torque: 89 lb. in (10 Nm)

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9. 1. Install the oil pump drive chain tensioner and bolt.

      Torque: 89 lb. in (10 Nm)

   2. Remove the pin.

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10. NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the RH side the triangle marks are used.
    1. Install the RH timing chain with the single colored links aligned with the triangle  timing marks on the VCT units.
    2. Install the double colored links so they straddle the timing mark on the crankshaft sprocket.

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11. Install the RH timing chain guide and bolts.

    Torque: 89 lb. in (10 Nm)

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12. Install the RH timing chain tensioner arm.

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13. Slide the tensioner cylinder out of the RH timing chain tensioner housing.

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14. NOTE: Use vise jaw protectors or cover the jaws of the vise with clean shop towels to prevent damage to the surface of the tensioner ratchet mechanism.

    Mount the flat machined surfaces on the end of the tensioner cylinder into a vise.

    1. Using a flat-bladed screwdriver apply light downward pressure on the end of the tensioner ratchet mechanism. Use the General Equipment: Vise Use the General Equipment: Vise Jaw Protectors Use the General Equipment: Flat-Bladed Screwdriver
    2. Rotate the screwdriver clockwise approximately one turn.
    3. An audible click will be heard when the tensioner ratchet mechanism locks into place.

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15. Slide the tensioner cylinder into the tensioner housing until it contacts the bottom of the bore. The shoulder of the tensioner cylinder will be flush with the top of the housing.

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16. 1. Firmly press the tensioner cylinder into the tensioner housing until the shoulder of the tensioner cylinder is approximately 3 mm (0. 125 in) below the top of the housing.
    2. Install a retaining pin into the hole in the housing to lock the tensioner cylinder in the retracted position.

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17. 1. Position the RH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.
    2. Install the bolts.

       Torque: 89 lb. in (10 Nm)

    3. Remove the pin to allow the tensioner cylinder to extend and press against the timing chain tensioner arm.

    Courtesy of FORD MOTOR COMPANY

18. Install new engine front cover gaskets.

    Courtesy of FORD MOTOR COMPANY

19. Lubricate and install a new oil gallery seal (6G068).

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

    Courtesy of FORD MOTOR COMPANY

20. NOTE: Failure to Use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    Apply a 9 mm (0. 35 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the cylinder block skirt-to-cylinder block joint and the cylinder head-to-cylinder block joint areas as indicated.

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

    Courtesy of FORD MOTOR COMPANY

21. NOTE: Failure to Use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    Apply a 4. 5 mm (0. 18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.

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

    Courtesy of FORD MOTOR COMPANY

22. Install the engine front cover and the fasteners.

    Torque:

    Stage 1: Tighten bolts 1 through 11 to: 18 lb. ft (24 Nm)

    Stage 2: Tighten bolts 12 through 13 to: 35 lb. ft (48 Nm)

    Stage 3: Tighten bolts 14 through 21 to: 18 lb. ft (24 Nm)

    Fig 2: Engine Front Cover Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
23. Lubricate the engine front cover bore with clean engine oil.

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

    Courtesy of FORD MOTOR COMPANY

24. 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.

    Courtesy of FORD MOTOR COMPANY

25. Lubricate the crankshaft front seal inner lip with clean engine oil.

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

    Courtesy of FORD MOTOR COMPANY

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

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

    Courtesy of FORD MOTOR COMPANY

27. 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.

    Courtesy of FORD MOTOR COMPANY

28. NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).

    Using a universal pulley holder, install and tighten a new crankshaft pulley bolt.

    Torque:

    Stage 1: 166 lb. ft (225 Nm)

    Stage 2: Loosen: 360 °

    Stage 3: 26 lb. ft (35 Nm)

    Stage 4: 270 °

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29. Rotate the crankshaft pulley bolt clockwise to position the camshaft lobe upward for the camshaft roller follower to be installed.

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

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

    Courtesy of FORD MOTOR COMPANY

31. Install a new gasket.

    Courtesy of FORD MOTOR COMPANY

32. Apply clean engine oil to the surface.

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

    Courtesy of FORD MOTOR COMPANY

33. NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 8 mm (0. 31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.

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

    Courtesy of FORD MOTOR COMPANY

34. Install the valve cover and tighten the bolts.

    Torque: 89 lb. in (10 Nm)

    Fig 3: Valve Cover Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
35. NOTE: Installation of new seals is only required if damaged seals were removed.

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

    Courtesy of FORD MOTOR COMPANY

36. Install a new gasket.

    Courtesy of FORD MOTOR COMPANY

37. Apply clean engine oil to the surface.

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

    Courtesy of FORD MOTOR COMPANY

38. NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 8 mm (0. 31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.

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

    Courtesy of FORD MOTOR COMPANY

39. Install the valve cover and tighten the bolts.

    Torque: 89 lb. in (10 Nm)

    Fig 4: Valve Cover Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
40. Install a new oil pump seal.

    Courtesy of FORD MOTOR COMPANY

41. NOTE: Failure to Use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The oil pan must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.
    1. Apply a 4. 5 mm (0. 18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the new oil pan.

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

    2. Apply a 9 mm (0. 35 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-cylinder block joint areas on the new oil pan.

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

    3. Inspect the crankcase ventilation passages to make sure they are not blocked by any sealer applied.

    Courtesy of FORD MOTOR COMPANY

42. Install the new oil pan and the bolts.

    Torque: 89 lb. in (10 Nm)

    Fig 5: Oil Pan Tightening Sequence

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43. Install the new TC oil return tube-to-engine block gasket.

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44. Install a new TC oil return tube O-ring seal and then lubricate with clean engine oil.

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

    Courtesy of FORD MOTOR COMPANY

45. NOTE: AWD displayed FWD is similar.

    Install the TC oil return tube and the bolts.

    Torque: 89 lb. in (10 Nm)

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46. Install the new TC oil return tube-to-engine block gasket.

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47. Install a new TC oil return tube O-ring seal and then lubricate with clean engine oil.

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

    Courtesy of FORD MOTOR COMPANY

48. Install the TC oil return tube, then install and tighten the bolts.

    Torque: 89 lb. in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

49. • Lubricate the inside and the outside diameter of the grommet with clean engine coolant.

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

    • Install the grommet so it is flush with the rear of the coolant pump housing.

    Courtesy of FORD MOTOR COMPANY

50. NOTE: Verify the front cover dowel pins are aligned to the coolant pump and that the coolant pump is fully seated prior to installing the fasteners.
    • Using a new gasket, install the coolant pump and the fasteners.

      Torque:

      Fasteners 1-7:

      Stage 1: 89 lb. in (10 Nm)

      Stage 2: 45 °

    • Torque: Fastener 8: 18 lb. ft (24 Nm)
    Fig 6: Coolant Pump Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
51. Install the gasket, the throttle body and the bolts.

    Torque: 89 lb. in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

52. Inspect and replace any ignition coil-on-plugs that have rubber boots with cracks, rips or tears.

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53. 1. Install the ignition coil-on-plugs.
    2. Install and tighten the ignition coil-on-plug stud bolts.

       Torque: 53 lb. in (6 Nm)

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54. Install the oil level indicator.

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55. Install the EVAP purge valve and connect the quick release coupling. Refer to : Quick Release Coupling .

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56. 1. Install the vacuum tube assembly onto the engine and connect the vacuum hose and clamp to the TC.
    2. Install the vacuum control solenoid bolts.

       Torque: 62 lb. in (7 Nm)

    3. Connect the vacuum tube quick release coupling. Refer to : Quick Release Coupling .
    4. Attach the vacuum hose retainers.

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57. Connect the vacuum hose and clamp to the TC.
    • Attach the vacuum hose retainers.

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58. Install the engine wiring harness onto the engine.
    • Connect the engine wiring harness electrical connectors and attach the retainers.

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59. • Connect the engine wiring harness electrical connectors and attach the wiring harness retainers.
    • Slide the insulator down over the CHT electrical connector.

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60. 1. Install the vacuum harness pressure sensor bolt.

       Torque: 62 lb. in (7 Nm)

    2. Connect the MAP sensor electrical connector.
    3. Attach the wiring harness and vacuum harness retainers.

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61. Connect the engine wiring harness electrical connectors and attach the retainers.

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62. 1. Install the EVAP purge valve onto the intake manifold mounting tab.
    2. Disconnect the EVAP tube quick release coupling. Refer to : Quick Release Coupling .
    3. Connect the EVAP purge valve electrical connector.

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63. Install the EVAP tube and connect the quick release coupling. Refer to: Quick Release Coupling .

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64. • Install the PCV tube and connect the quick release coupling. Refer to: Quick Release Coupling .
    • Connect the crankcase pressure sensor electrical connector.
    • Attach the PCV tube retainer.

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65. • Install the PCV tube and connect the quick release couplings. Refer to : Quick Release Coupling .
    1. Connect the throttle body electrical connector and attach the wiring harness retainer.

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66. • Install the ground wire and stud bolt.

      Torque: 89 lb. in (10 Nm)

    • Connect the high pressure fuel pump electrical connector.
    • Attach the wiring harness retainers.

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67. Attach the wiring harness retainers.

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68. • Install the oil pressure control solenoid and the retainer.

      Torque: 97 lb. in (11 Nm)

    • Disconnect the oil pressure control solenoid electrical connector.

    Courtesy of FORD MOTOR COMPANY

69. • Install the generator stud.

      Torque: 71 lb. in (8 Nm)

    • Install the generator and the bolt.

      Torque: 35 lb. ft (47 Nm)

    • Install the coolant pump pulley and the bolts.

      Torque: 89 lb. in (10 Nm)

    • Install the idler pulley and bolt.

      Torque: 35 lb. ft (48 Nm)

    • Install the accessory drive belt tensioner and the bolts.

      Torque: 18 lb. ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

70. Using a floor crane, remove the engine from the mounting stand. Install Special Service Tool: 303-1634 Lift Eyes (2)., 303-1246 Engine Spreader Bar. Use the General Equipment: Floor Crane Use the General Equipment: Mounting Stand

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71. Lubricate the crankshaft rear seal lips with clean engine oil.

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

    Courtesy of FORD MOTOR COMPANY

72. NOTE: The crankshaft rear seal and retainer plate must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    Apply a 4. 5 mm (0. 18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the crankshaft rear seal and retainer plate.

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

    Courtesy of FORD MOTOR COMPANY

73. • 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 and retainer plate onto the tool and into the installed position.

    Courtesy of FORD MOTOR COMPANY

74. Install the crankshaft rear seal retainer plate bolts. Remove Special Service Tool: 303-1250 Seal Installer, Rear Main.

    Torque: 89 lb. in (10 Nm)

    Fig 7: Crankshaft Rear Seal Retainer Plate Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
75. 1. Install the CKP sensor and the bolt.

       Torque: 89 lb. in (10 Nm)

    2. Connect the CKP sensor electrical connector.

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76. Install the crankshaft sensor ring.

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77. 1. Position the flexplate on the crankshaft.
    2. Install the bolts then rundown the bolts one turn at a time in sequence displayed below until the flexplate is snug against the rear face of the crankshaft.
    3. Final tighten the bolts in sequence displayed below.

       Torque: 59 lb. ft (80 Nm)

    Fig 8: Flexplate Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
78. Install the engine into the vehicle. Refer to : Engine .