Section 37 (ENGINE - 3.5L DURATEC (212kW/278PS)): Assembly: Engine
For information on Ford Color Coded Illustrations refer to OEM Color Coding
Special Tool(s) / General Equipment
| 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge | |
|---|---|
| 205-142 (T80T-4000-J) Installer, Differential Bearing Cone | |
| 205-153 (T80T-4000-W) Handle | |
| 303-102 Installer, Crankshaft Pulley | |
| 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F | |
| 303-1245 Engine Lift Eye TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1248 Camshaft holding tools TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1251 Installer, Front Seal TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1529 Lift Eye, Engine TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW | |
| 303-1530 Tool, Chain Tensioner Hold Down TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW | |
| 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal TKIT-1988-FLM TKIT-1988-F | |
| 307-399 Alignment Pins, Transmission Fluid Pump TKIT-2002N-DEW TKIT-2000AP-FLM/LM | |
| Feeler Gauge | |
| Strap Wrench | |
| Floor Crane | |
| Mounting Stand | |
| Hose Clamp Remover/Installer | |
| Round-Ended Steel Rule | |
| Piston Ring Compressor |
Materials
| Name | Specification |
|---|---|
| Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil XO-5W20-QSP | WSS-M2C945-A |
| Motorcraft® Thread Sealant with PTFE TA-24-B | WSK-M2G350-A2 |
| Motorcraft® High Performance Engine RTV Silicone TA-357 | WSE-M4G323-A6 |
| Motorcraft® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft® Metal Surface Prep Wipes ZC-31-B | - |
| Motorcraft® Orange Concentrated Antifreeze/Coolant VC-3-B | WSS-M97B44-D |
- Using a hex bit, install the oil piston cool valves.
Torque: 35 lb.in (4 Nm)
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NOTE: This step is for selecting the correct main bearings.NOTE: The #1 main bearing is at the front of the engine block.
- Select the crankshaft main bearings for each crankshaft journal.
- Record the code that is on the cylinder block face.
- Record the code that is on the crankshaft flange.
- The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.
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NOTE: This chart is continued in the next step.NOTE: This chart is for selecting main bearings 1 and 4 only.
- Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4.
- Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
- Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.
- As an example, if the engine block code letter is "M" and the crankshaft code letter is "M", the correct bearing grade for this main bearing is a "2" for the upper bearing and a "2" for the lower bearing.
- Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
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NOTE: This chart is for selecting main bearings 1 and 4 only.
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NOTE: This chart is continued in the next step.NOTE: This chart is for selecting main bearings 2 and 3 only.
- Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3.
- Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.
- Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing.
- As an example, if the engine block code letter is "N" and the crankshaft code letter is "H", the correct bearing grade for this main bearing is "2".
- Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
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NOTE: This chart is for selecting main bearings 2 and 3 only.
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NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.NOTE: Use the original connecting rod cap bolts.
Using the original rod cap bolts, install the connecting rod caps and bolts.
Torque: Stage 1: 17 lb.ft (23 Nm) Stage 2: 32 lb.ft (43 Nm) Stage 3: 90 deg.
- Measure the connecting rod large end bore in 2 directions.
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- Remove the bolts and the rod cap.
- Discard the bolts.
- Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
- Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
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NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
Lubricate the upper crankshaft main bearings with clean engine oil and install in the cylinder block.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
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NOTE: Do not install the upper thrust bearings until the crankshaft is installed.NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.
Install the crankshaft.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
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NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.
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NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.
- Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Check the seating and squareness of the bearings to make sure of proper seating in the caps.
- Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
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NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.
- Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
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NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.
Tighten the main bearing bolts.
Torque: Stage 1: 24 lb.ft (33 Nm) Stage 2: 135 deg.
- Install the new main bearing cap side bolts.
Torque: Stage 1: 33 lb.ft (45 Nm) Stage 2: 90 deg.
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- Position the crankshaft to the rear of the cylinder block. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Zero the Dial Indicator Gauge.
- Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play.
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NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
- Prepare the connecting rod and cap.
- Insert the new bolts in the rod cap.
- Insert the upper and lower rod bearings into the rod and cap.
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- Center line of the piston parallel to the wrist pin bore.
- Upper compression ring gap location.
- Upper oil control segment ring gap location.
- Lower oil control segment ring gap location.
- Expander ring and lower compression ring gap location.
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NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.NOTE: Make sure the piston rings are positioned to specifications for installation. Refer to Piston .NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.
Using the Piston Ring Compressor, install the piston and the connecting rod assemblies. Repeat until all 6 piston assemblies are installed. Use the General Equipment: Piston Ring Compressor
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
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NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation.
Install the connecting rod cap and the new bolts.
Torque: Stage 1: 17 lb.ft (23 Nm) Stage 2: 32 lb.ft (43 Nm) Stage 3: 90 deg.
- Install the main bearing cap support brace and the new bolts.
Torque: Stage 1: 18 lb.ft (24 Nm) Stage 2: 180 deg.
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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.
Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
- Lubricate the crankshaft rear seal with clean engine oil.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- Install the crankshaft rear seal and the bolts.
Torque: 89 lb.in (10 Nm)
- Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
- Install the oil pump and the bolts.
Torque: 89 lb.in (10 Nm)
- Install a new oil pump screen and pickup tube O-ring seal.
- Install the oil pump screen and pickup tube and the bolts.
Torque: 89 lb.in (10 Nm)
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NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.
Install the A/C compressor and the stud bolts.
Torque: 18 lb.ft (25 Nm)
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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan.
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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
- Install the oil pan and the bolts.
Torque: Stage 1: 27 lb.in (3 Nm) Stage 2: Loosen: 180 deg.
- Position the oil pan so the mounting boss is against the A/C compressor and using a Ended Steel Rule, align the oil pan flush with the rear of the cylinder block at the 2 areas shown. Use the General Equipment: Round-Ended Steel Rule
- Tighten the bolts in the sequence shown.
Torque: 27 lb.in (3 Nm)
- Install the remaining oil pan bolts.
Torque: Stage 1: Tighten bolts 1-9 and 11-14 to: 18 lb.ft (24 Nm) Stage 2: Tighten bolt 10 to: 177 lb.in (20 Nm) Stage 3: Tighten bolt 10 an additional : 90 deg. Stage 4: Tighten bolt 15 and 16 to: 89 lb.in (10 Nm)
- Install the A/C compressor bolt.
Torque: 18 lb.ft (25 Nm)
- Install the coolant pump and the bolts.
Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.
- Install the KS and the bolts.
Torque: 177 lb.in (20 Nm)
- Install the RH cylinder head gasket.
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NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.
Install the RH cylinder head and the new bolts.
Torque: Stage 1: 177 lb.in (20 Nm) Stage 2: 26 lb.ft (35 Nm) Stage 3: 90 deg. Stage 4: 90 deg. Stage 5: 45 deg.
- Install the M6 bolt.
Torque: 89 lb.in (10 Nm)
- Install the LH cylinder head gasket.
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NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.
Install the LH cylinder head and the new bolts.
Torque: Stage 1: 177 lb.in (20 Nm) Stage 2: 26 lb.ft (35 Nm) Stage 3: 90 deg. Stage 4: 90 deg. Stage 5: 45 deg.
- Install the M6 bolt.
Torque: 89 lb.in (10 Nm)
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NOTE: The valve tappets must be installed in their original positions.NOTE: Coat the valve tappets with clean engine oil prior to installation.NOTE: RH shown, LH similar.
Install the valve tappets.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
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NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.
Position the crankshaft dowel pin in the 9 o'clock position.
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NOTE: Coat the camshafts with clean engine oil prior to installation.
Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral position as shown.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
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NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the RH camshaft seal gaps as shown.
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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the camshaft caps, oil tube and the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 45 deg.
- Loosen the camshaft cap bolts.
- Tighten the camshaft cap bolts.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 45 deg.
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NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Adjustment . Use the General Equipment: Feeler Gauge
- Install the RH primary timing chain guide and the bolt.
Torque: 89 lb.in (10 Nm)
- Remove the bolts and the oil tube.
- Rotate the RH camshafts to TDC.
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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 303-1248 Camshaft holding tools.
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NOTE: The VCT oil control solenoids are removed for clarity.
Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- Align the colored links with the timing marks and assemble the RH VCT units.
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NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.
Position the RH VCT units and the secondary timing chain onto the camshafts by aligning the holes in the VCT units with the dowel pins in the camshafts.
- Install the new RH VCT unit bolts.
Torque: Stage 1: 30 lb.ft (40 Nm) Stage 2: Loosen: 1turn(s) Stage 3: 18 lb.ft (25 Nm) Stage 4: 180 deg.
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NOTE: Make sure the secondary timing chain is centered on the timing chain tensioner guides.NOTE: The VCT oil control solenoids are removed for clarity.
Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
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NOTE: Coat the camshafts with clean engine oil prior to installation.
Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral position as shown.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
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NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the LH camshaft seal gaps as shown.
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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the camshaft caps, oil tube and the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 45 deg.
- Loosen the camshaft cap bolts.
- Tighten the camshaft cap bolts.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 45 deg.
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NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Adjustment . Use the General Equipment: Feeler Gauge
- Remove the bolts and the oil tube.
- Rotate the LH camshafts to TDC.
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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 303-1248 Camshaft holding tools.
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NOTE: The VCT oil control solenoids are removed for clarity.
Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- Align the colored links with the timing marks and assemble the LH VCT units.
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NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.
Position the LH VCT units and the secondary timing chain onto the camshafts by aligning the holes in the VCT units with the dowel pins in the camshafts.
- Install the new LH VCT unit bolts.
Torque: Stage 1: 30 lb.ft (40 Nm) Stage 2: Loosen: 1turn(s) Stage 3: 18 lb.ft (25 Nm) Stage 4: 180 deg.
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NOTE: Make sure the secondary timing chain is centered on the timing chain tensioner guides.NOTE: The VCT oil control solenoids are removed for clarity.
Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- Install the upper LH timing chain guide and the bolt.
Torque: 89 lb.in (10 Nm)
- Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
- Install the crankshaft sprocket.
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NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.
Install the timing chain with the colored links aligned with the timing marks on the VCT units and the crankshaft sprocket.
- Install the lower LH timing chain guide and the bolts.
Torque: 89 lb.in (10 Nm)
- Install the timing chain tensioner arm.
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- Position the tensioner in a soft-jawed vise.
- Using pliers, squeeze the ends of the ratchet wire clip together.
- Using the soft-jawed vise, compress the plunger to the reset position.
- Install a locking pin in the 2 holes of the tensioner body to hold the plunger in place.
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NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.
- Install the timing chain tensioner and the bolts.
Torque: 89 lb.in (10 Nm)
- Remove the lockpin.
- Install the timing chain tensioner and the bolts.
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- As a post-check, verify correct alignment of all timing marks.
- There are 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
- There are 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
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NOTE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
Install the VCT oil control solenoids and the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 20 deg.
- Remove Special Service Tool: 303-1248 Camshaft holding tools.
- Install the RH oil tube and the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 60 deg.
- Remove Special Service Tool: 303-1248 Camshaft holding tools.
- Install the LH oil tube and the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 60 deg.
- Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.NOTE: The engine front cover and bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
- Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder block joint areas of the engine front cover in places as indicated.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.
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NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and the bolts.
Torque: 27 lb.in (3 Nm)
- Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
- Install the remaining engine front cover bolts.
Torque: Stage 1: Tighten bolts 1 thru 22 to: 89 lb.in (10 Nm) Stage 2: Tighten bolts 23, 24 and 25 to: 133 lb.in (15 Nm) Stage 3: Tighten bolt 26 to: 89 lb.in (10 Nm) Stage 4: Loosen bolt 26: 1turn(s) Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lb-ft) plus an additional: 90 deg. Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional: 45 deg. Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional: 45 deg.
- Install the CHT jumper harness.
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NOTE: Installation of new seals is only required if damaged seals were removed.
If removed, using the special tools, install the spark plug tube seals. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer, 205-153 (T80T-4000-W) Handle.
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NOTE: Installation of new seals is only required if damaged seals were removed.
If removed, using the special tools, install the VCT oil control solenoid seals. Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone, 205-153 (T80T-4000-W) Handle.
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NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install a new valve cover gasket.
- Install the valve cover and tighten the bolts.
Torque: 89 lb.in (10 Nm)
- Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
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NOTE: Installation of new seals is only required if damaged seals were removed.
If removed, using the special tools, install the spark plug tube seals. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer, 205-153 (T80T-4000-W) Handle.
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NOTE: Installation of new seals is only required if damaged seals were removed.
If removed, using the special tools, install the VCT oil control solenoid seals. Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone, 205-153 (T80T-4000-W) Handle.
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NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install a new valve cover gasket.
- Install the valve cover and tighten the bolts.
Torque: 89 lb.in (10 Nm)
- Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
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- Install the coil-on-plugs and the bolts.
Torque: Stage 1: 62 lb.in (7 Nm) Stage 2: 50 deg.
- Install the oil level indicator.
- Install the coil-on-plugs and the bolts.
- Install the oil pressure switch.
Material: Motorcraft® Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)
Torque: Stage 1: 124 lb.in (14 Nm) Stage 2: 180 deg.
- Install a new oil filter adapter gasket.
- Install the oil filter adapter and the bolts.
Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.
- Install a new oil cooler O-ring gaskets.
- Install the oil cooler and the bolts.
Torque: 89 lb.in (10 Nm)
- Install the CKP sensor and bolt.
Torque: 89 lb.in (10 Nm)
- Install new O-ring seals and apply clean coolant the O-rings.
Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)
- Install the coolant tube assembly.
- Install the new lower intake manifold gaskets.
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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: Make sure that the fuel rail and the fuel injectors do not come out of the lower intake manifold.
Install the lower intake manifold and the bolts.
Torque: 89 lb.in (10 Nm)
- Install the thermostat housing bolts.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 90 deg.
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NOTE: Apply clean engine oil to the CMP sensor O-ring seals.
Install the RH CMP sensors and bolts.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
Torque: 89 lb.in (10 Nm)
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NOTE: Apply clean engine oil to the CMP sensor O-ring seals.
Install the LH CMP sensors and bolts.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
Torque: 89 lb.in (10 Nm)
- Install the cover and the pin-type retainer.
- Install the LH block coolant drain plug.
Torque: Stage 1: 142 lb.in (16 Nm) Stage 2: 180 deg.
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- Install the RH block coolant drain plug or block heater.
Torque: Stage 1: Tighten the cylinder block drain plug to: 89 lb.in (10 Nm) Stage 2: Plus an additional: 720 deg.
- Tighten the block heater to:
Torque: 41 lb.ft (55 Nm)
- Install the RH block coolant drain plug or block heater.
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- Install the new studs.
Torque: 106 lb.in (12 Nm)
- Install the new exhaust manifold gasket.
- Install the new studs.
- Install the LH catalytic converter and the 3 new lower nuts finger tight.
Torque: Stage 1: Install the 3 new upper LH catalytic converter nuts and tighten to: 18 lb.ft (25 Nm) Stage 2: Tighten the 3 lower LH catalytic converter nuts to: 18 lb.ft (25 Nm)
- Install the heat shield and the bolts.
Torque: 97 lb.in (11 Nm)
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- Install the generator and the stud.
Torque: 71 lb.in (8 Nm)
- Install the nut and bolt.
Torque: 35 lb.ft (48 Nm)
- Install the generator and the stud.
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- Position the engine wire harness on the engine.
- Connect the RH electrical connectors and the wire harness retainers.
- Connect the CHT electrical connector.
- Connect the RH CMP and KS electrical connectors. Connect the wire harness retainer.
- Install the engine vent hose. Use the General Equipment: Hose Clamp Remover/InstallerNOTE: 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.
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NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold bracket and bolt.
Torque: 89 lb.in (10 Nm)
- Install the upper intake manifold gaskets.
- Install the upper intake manifold and the bolts.
Torque: Tighten bolts 1 and 3-7 to 10 Nm (89 lb-in) plus an additional: : 45 deg. Tighten bolt 2 to 10 Nm (89 lb-in) plus an additional: : 90 deg.
- Install the upper intake manifold bracket bolt.
Torque: 89 lb.in (10 Nm)
- Connect the engine vent hose. Use the General Equipment: Hose Clamp Remover/Installer
- Connect the retainers for the coolant hose.
- Connect the wire retainer and the electrical connector.
- Connect the wire retainer and the electrical connectors.
- Connect the CKP sensor electrical connector.
- Position back the wire harness grommet.
- Install the wiring harness retainer stud bolt.
Torque: 89 lb.in (10 Nm)
- Install the heat shield, nut and bolt.
Torque: 97 lb.in (11 Nm)
- Connect the LH CMP and the CMS (catalyst monitor sensor) electrical connectors. Connect the wire harness retainers.
- Connect the wire retainer and the electrical connector.
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- Position the engine wire harness on the engine.
- Connect the LH electrical connectors and the wire harness retainers.
- Install the crankcase vent tube.
- Install the accessory drive belt tensioner and the bolts.
Torque: 97 lb.in (11 Nm)
- Lubricate the crankshaft front seal bore with clean engine oil.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- Using the special tool, install the crankshaft front seal. Use Special Service Tool: 303-102 Installer, Crankshaft Pulley, 303-1251 Installer, Front Seal.
- Lubricate the crankshaft front seal and the crankshaft pulley with clean engine oil.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-102 Installer, Crankshaft Pulley, 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal.
- Install the new crankshaft bolt and the washer. Use the General Equipment: Strap Wrench
Torque: Stage 1: 89 lb.ft (120 Nm) Stage 2: Loosen: 1 turn(s) Stage 3: 37 lb.ft (50 Nm) Stage 4: 90 deg.
- Install Special Service Tool: 303-1529 Lift Eye, Engine.
- Install Special Service Tool: 303-1245 Engine Lift Eye.
- Install the floor crane. Use the General Equipment: Floor Crane
- Remove the engine from the mounting stand. Use the General Equipment: Mounting Stand
- Install the crankshaft sensor ring.
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NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position
Using the special tool, install the flexplate and the bolts.
Torque: 59 lb.ft (80 Nm)
- Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
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