Section 53 (Engine - 1.0L ECOBOOST (92KW/125PS)): Assembly: Engine

WARNING: This page is about a different car, the 2018 Ford EcoSport. However, it is still accessible from the selected car via links, so may be relevant.

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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	303-1567Sizer, Teflon SealTKIT-2010C-FLM
Courtesy of FORD MOTOR COMPANY	303-1602Locking Tool, Crankshaft
Courtesy of FORD MOTOR COMPANY	303-1603Installer, Front Cover Seal
Courtesy of FORD MOTOR COMPANY	303-1604Timing Peg, Crankshaft TDC
Courtesy of FORD MOTOR COMPANY	303-1605Alignment Tool, Camshaft
Courtesy of FORD MOTOR COMPANY	303-1606Locking Tool, Variable Camshaft Timing
Courtesy of FORD MOTOR COMPANY	303-1611Torque Multiplier
Courtesy of FORD MOTOR COMPANY	303-1611-01Adapter for 303-1611
Courtesy of FORD MOTOR COMPANY	303-1611-02Adapter for 303-1611, Torque MultiplierTKIT-2014A-FLTKIT-2014A-ROW
Courtesy of FORD MOTOR COMPANY	310-207Installer, Fuel Injector Seal AssemblyTKIT-2009A-FLM
Feeler Gauge
Lifting Bracket
Floor Crane
Polydrive Bit Socket
Hose Clamp Remover/Installer
6 mm Drill Bit
Piston Ring Compressor
Punch
4 mm Drill Bit

Materials

Name	Specification
Motorcraft® High Performance Engine RTV SiliconeTA-357	WSE-M4G323-A6
Motorcraft® Gasket MakerTA-16	WSK-M2G348-A5

NOTE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Install the engine piston oil cooler valves and the bolts.
Torque 89 lb.in (10 Nm)

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NOTE: Make sure that the component is clean, free of foreign material and lubricant.
1. Measure the diameter in two directions.
2. Record the smallest measurement for each crankshaft main bearing journal.
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NOTE: Make sure that the components are installed to the position noted before removal.
1. Using the original bolts, install the main bearing caps and the bolts finger tight.
2. Torque
  Stage 1: 89 lb.in (10 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 22 lb.ft (30 Nm) Stage 4: 90 deg.
Fig 1: Main Bearing Caps Bolts Tightening Sequence
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NOTE: Make sure that the component is clean, free of foreign material and lubricant.

Measure each crankshaft block main bearing bore diameter.

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1. NOTE: The upper specification is the maximum oil clearance and the lower specification is the minimum oil clearance.
  
  Crankshaft journal diameter
2. Cylinder block bore diameter
- Using the chart, select the correct grade main bearings.
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NOTE: Make sure that the components are installed to the position noted before removal.

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 deg.

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NOTE: Make sure that the component is clean, free of foreign material and lubricant.
1. Measure the diameter in two directions.
2. Record the smallest measurement for each connecting rod.
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NOTE: Note the position of the components before removal.
1. Remove the bolts and the connecting rod caps.
2. Discard the bolts.
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NOTE: Make sure that the component is clean, free of foreign material and lubricant.
1. Measure the diameter in two directions.
2. Record the smallest measurement for each connecting rod journal.
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1. NOTE: The upper specification is the maximum oil clearance and the lower specification is the minimum oil clearance.
  
  Crankshaft connecting rod journal diameter
2. Connecting rod bore diameter
- Using the chart, select the correct grade connecting rod bearings for each crankshaft connecting rod journal.
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NOTE: Note the position of the components before removal.
1. Remove the bolts and the main bearing caps.
2. Discard the bolts.
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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.

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

NOTE: Component(s) must be lubricated with clean engine oil.

Lubricate with clean engine oil and install crankshaft main bearings.

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

NOTE: Component(s) must be lubricated with clean engine oil.

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

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NOTE: Component(s) must be lubricated with clean engine oil.

Lubricate with clean engine oil and install the crankshaft.

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

NOTE: Make sure that new bolts are installed.

Install the main bearing caps and the bolts.

Torque Stage 1: 89 lb.in (10 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 22 lb.ft (30 Nm) Stage 4: 90 deg.

Fig 2: Main Bearing Caps Bolts Tightening Sequence
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1. Position the crankshaft to the rear of the cylinder block.
2. Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
3. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
4. If the crankshaft end play exceeds the specified range, install new parts as necessary. Refer to: Specifications .
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NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

NOTE: Component(s) must be lubricated with clean engine oil.

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

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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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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.

NOTE: Component(s) must be lubricated with clean engine oil.

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

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

NOTE: Make sure that new bolts are installed.

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 deg.

Fig 3: Connecting Rod Caps Bolts Tightening Sequence
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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.

NOTE: Make sure that new bolts are installed.

NOTE: Install all the bolts finger tight before final tightening.
- 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)
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Install the alignment dowels.

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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.
Fig 4: Flexplate Bolts Tightening Sequence
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NOTE: Only rotate the crankshaft clockwise.

Rotate the crankshaft until piston No. 1 is approximately 35 deg. before top dead center (BTDC).

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Remove the engine plug bolt.

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

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NOTE: Only rotate the crankshaft clockwise.

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

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Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
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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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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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)

Fig 5: Oil Pump Bolts Tightening Sequence
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Install the oil pump belt tensioner and the bolts.
Torque 89 lb.in (10 Nm)

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1. Lubricate with clean engine oil and install the oil pump drive pulley.
2. Using a suitable tool, rotate the oil pump belt tensioner.
3. Install the oil pump belt.
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NOTE: Make sure that the component is installed to the position noted before removal.

Install the balance shaft weight.

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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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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)

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Tighten the balance shaft gear bolt.
Torque 26 lb.ft (35 Nm)

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

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NOTE: Make sure that the component is correctly installed.

Install the oil pump cover.

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Install the alignment dowels.

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Install a new cylinder head gasket.

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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 deg. Stage 4: 22 lb.ft (30 Nm) Stage 5: 90 deg. Stage 6: 90 deg.
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NOTE: Make sure that the components are installed to the position noted before removal.

NOTE: Component(s) must be lubricated with clean engine oil.

Lubricate with clean engine oil and install the valve tappets.

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

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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.
2. Lubricate the camshaft journals and camshaft bearing caps with clean engine oil and install.
3. Install all the original 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)
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1. Rotate the camshafts and measure the valve clearances. Note each cylinder number and the valve clearances measured. Use the General Equipment: Feeler Gauge
2. Compare the measured valve clearance(s) with the specifications. Refer to: Specifications .
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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.
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- 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).
- 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

Use the chart to determine the correct size valve tappet.

Number on underside of Tappet	Grade/Thickness
700	0.1063 in (2.7 mm)
725	0.1073 in (2.725 mm)
750	0.1083 in (2.75 mm)
775	0.1093 in (2.775 mm)
800	0.1102 in (2.8 mm)
825	0.1112 in (2.825 mm)
850	0.1122 in (2.85 mm)
875	0.1132 in (2.875 mm)
900	0.1142 in (2.9 mm)
925	0.1152 in (2.925 mm)
950	0.1161 in (2.95 mm)
975	0.1171 in (2.975 mm)
000	0.1181 in (3 mm)
025	0.1191 in (3.025 mm)
050	0.1201 in (3.05 mm)
075	0.1211 in (3.075 mm)
100	0.1220 in (3.1 mm)
125	0.1230 in (3.125 mm)
150	0.1240 in (3.15 mm)
175	0.1250 in (3.175 mm)
200	0.1260 in (3.2 mm)
222	0.1269 in (3.222 mm)
250	0.1280 in (3.25 mm)
275	0.1289 in (3.275 mm)
302	0.1300 in (3.302 mm)
325	0.1309 in (3.325 mm)
342	0.1316 in (3.342 mm)
375	0.1329 in (3.375 mm)
400	0.1339 in (3.4 mm)
425	0.1348 in (3.425 mm)
462	0.1363 in (3.462 mm)
475	0.1368 in (3.475 mm)
502	0.1379 in (3.502 mm)
525	0.1388 in (3.525 mm)
550	0.1398 in (3.55 mm)
575	0.1407 in (3.575 mm)

Install the correct valve tappet.
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)

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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)

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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.
2. Lubricate the camshaft journals and camshaft bearing caps with clean engine oil and install.
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)
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1. Install the special service tool and the mounting bolts loosely. Use Special Service Tool: 303-1605 Alignment Tool, Camshaft.
2. Tighten the camshaft alignment tool camshaft bolts until each camshaft is held securely.
3. Tighten the camshaft alignment tool mounting bolts.
  Torque 89 lb.in (10 Nm)
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NOTE: If installing a new component, determine the part number.

Install the VCT units.

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1. Install Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.
2. Align the tools to the 12 o'clock position.
3. NOTE: Ensure that the installation marks are aligned and orientated to a 12 o'clock position.
View a video version of this procedure below.

multimedia:A supplement to the article is available.

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NOTE: Make sure that new bolts are installed.

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

Install the VCT units mounting bolt.

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

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NOTE: Make sure that the component is installed to the position noted before removal.
1. Lubricate with clean engine oil and install the timing drive pulley.
2. Install the oil supply filter and the bolt.
  Torque 80 lb.in (9 Nm)
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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)

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NOTE: If installing a new component, determine the part number.

Install the timing belt in sequence shown.

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

Remove the locking pin.

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Install a new gasket.

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

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

Complete this step within: 10min Apply beads of silicone sealant that are 4 mm (0.157 in).

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

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NOTE: Make sure that new bolts are installed.

NOTE: Note the different lengths of the bolts.
1. Install the engine front cover and fasteners. Tighten in sequence in 3 stages.
- Stage 1:
  Torque 1-2, M6x60: 44 lb.in (5 Nm) 3-6, M10x95: 89 lb.in (10 Nm) 7-16, M6x60: 44 lb.in (5 Nm)
- Stage 2:
  Torque 3-6: 30 lb.ft (40 Nm) 3-4: 52 lb.ft (70 Nm) 5-6: 52 lb.ft (70 Nm) 1-2: 80 lb.in (9 Nm) 7-16: 133 lb.in (15 Nm)
- Stage 3:
  Torque 3-4: 90 deg. 5-6: 90 deg. 1-2: 90 deg. 7-16: 90 deg.
Fig 6: Engine Front Cover Bolts Tightening Sequence
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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.

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1. NOTE: Make sure the new O-ring seals are seated correctly.
  
  Install new O-ring seals.
2. Install the thermostat and the bolts.
  Torque 89 lb.in (10 Nm)
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Install the CKP and the bolt.
Torque 89 lb.in (10 Nm)

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Install Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.
Torque 89 lb.in (10 Nm)

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1. Turn until resistance is felt.
2. Tighten the bolts.
  Torque 133 lb.in (15 Nm)
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NOTE: Use an open-ended wrench to prevent the component from turning.

Tighten the bolts.

Torque 22 lb.ft (30 Nm)

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

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NOTE: Use an open-ended wrench to prevent the component from turning.

Tighten the bolts.

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

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NOTE: Only rotate the crankshaft clockwise.

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

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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.
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1. Install 3/16 inch punch. Use the General Equipment: Punch
2. Torque: Stage 1: 18 lb.ft (25 Nm) Stage 2: 52 lb.ft (70 Nm)
View a video version of this procedure below.

multimedia:A supplement to the article is available.

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

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1. M8x30
2. M8x25 Install Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier.
  Torque 18 lb.ft (24 Nm)
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Install Special Service Tool: 303-1611-01 Adapter for 303-1611.
Torque 18 lb.ft (24 Nm)

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NOTE: Only tighten the nut finger tight at this stage.

Install Special Service Tool: 303-1611 Torque Multiplier.

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1. Torque: 44 lb.ft (60 Nm)
2. Torque: Stage 1: 90 deg. Stage 2: 90 deg. Stage 3: 90 deg. Stage 4: 90 deg. Stage 5: 90 deg.
View a video version of this procedure below.

multimedia:A supplement to the article is available.

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Remove Special Service Tool: 303-1611 Torque Multiplier.

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1. 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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NOTE: Exhaust and A/C compressor removed from graphic for clarity.

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

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

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

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NOTE: Only rotate the crankshaft clockwise.

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

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

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NOTE: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

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1. NOTE: The tool can only be installed if the 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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Remove Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.

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Install the engine plug bolt.
Torque 177 lb.in (20 Nm)

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

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

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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

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

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

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1. NOTE: Make sure that new bolts are installed.
  
  NOTE: Note the different lengths of the bolts.
  
  Install the oil pan and the bolts. Tighten in sequence in 2 stages.
2. Stage 1:
  Torque 1-2, M6x20: 89 lb.in (10 Nm) 3, M6x75: 89 lb.in (10 Nm) 4-6, M6x20: 89 lb.in (10 Nm) 7, M6x75: 89 lb.in (10 Nm) 8-11, M6x20: 89 lb.in (10 Nm) 12-13, M6x100: 89 lb.in (10 Nm) 14, M6x75: 89 lb.in (10 Nm) 15, M6x20: 89 lb.in (10 Nm)
3. Stage 2:
  Torque 1-2: 89 lb.in (10 Nm) 3: 89 lb.in (10 Nm) 4-6: 89 lb.in (10 Nm) 7: 89 lb.in (10 Nm) 8-11: 89 lb.in (10 Nm) 12-13: 89 lb.in (10 Nm) 14: 89 lb.in (10 Nm) 15: 89 lb.in (10 Nm)
Fig 7: Oil Pain Bolts Tightening Sequence
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If equipped, install the shield and the fastener.
Torque 97 lb.in (11 Nm)

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NOTE: Make sure that the component is clean, free of foreign material and lubricant.
1. Apply beads of sealant as indicated.
  Material Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
2. Material
  Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)
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If required, install a new gasket.

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

Install the valve cover and the bolts.

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Tighten the bolts in sequence.
Torque 89 lb.in (10 Nm)

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1. NOTE: The O-ring seal is to be reused unless damaged.
  
  NOTE: Component must be lubricated with clean engine oil.
  
  Lubricate the O-ring seal.
2. NOTE: Make sure that new bolts are installed.
  
  Install the VCT solenoids and the bolts.
  
  Torque 62 lb.in (7 Nm)
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Install the oil level indicator.

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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)

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Install the oil pump control solenoid.
Torque 89 lb.in (10 Nm)

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Install a new oil pressure switch.
Torque 177 lb.in (20 Nm)

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NOTE: Make sure that the component is correctly installed.

Install the KS.

Torque 177 lb.in (20 Nm)

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

Install the intake manifold and the bolts.

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Tighten the bolts in sequence.
Torque 1-10: 89 lb.in (10 Nm)

Fig 8: Intake Manifold Bolts Tightening Sequence
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Install the crankcase vent tube.

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NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
1. Install the Teflon® Seal Guide onto the fuel injector tip. 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.
  
  Install the new Teflon® seals onto the Teflon® Seal Guide, using the Pusher Tool, slide the Teflon® seals along the Teflon® Seal Guide.
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.
4. Remove the special tools.
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NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
1. Massage and warm the Teflon® seal with your fingers before the Teflon® seal sizer tool is installed. This 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.
4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
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NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.
1. NOTE: The new the fuel injector support rings must be installed in the correct orientation with the wide surface area facing up against the fuel injector O-ring seals. Improperly installed support rings may cause the fuel system to leak.
  
  Install the new the fuel injector support rings.
2. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  Install the new fuel injector O-ring seals and lubricate them with clean engine oil. Refer to: Specifications .
3. NOTE: Make sure that new fuel injector clips are installed.
  
  Install the new the fuel injector clips.
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NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.

NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

Install the fuel injectors to the fuel rail.

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Connect the fuel rail wiring harness.

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1. NOTE: Only use moderate force.
  
  Install the fuel rail assembly.
2. NOTE: Only tighten the bolts finger tight at this stage.
  
  Tighten each bolt 1 turn at a time.
3. Attach the wiring harness retainers.
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Tighten in sequence.
Torque 17 lb.ft (23 Nm)

Fig 9: Fuel Rail Assembly Bolts Tightening Sequence
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1. NOTE: The O-ring seal is to be reused unless damaged.
  
  Lubricate the O-ring seals and install the CMP sensors.
2. Install the bolts.
  Torque 89 lb.in (10 Nm)
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NOTE: Install all the bolts finger tight before final tightening.

Install the coil-on-plugs and the bolts.

Torque 89 lb.in (10 Nm)

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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.

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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.

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1. NOTE: Use a new seal.
  
  NOTE: Component(s) must be lubricated with clean engine oil.
  
  Install a new O-ring seal and lubricate with clean engine oil.
2. NOTE: Only use moderate force.
  
  Install the high pressure fuel pump.
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1. NOTE: Make sure that new bolts are installed.
  
  NOTE: Only tighten the bolts finger tight at this stage.
  
  Tighten each bolt 0.5 turn at a time until seated.
2. Final tighten the bolts in 2 stages.
  Torque Stage 1: 44 lb.in (5 Nm) Stage 2: 115 lb.in (13 Nm)
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NOTE: Make sure that a new component is installed.

NOTE: Only tighten the 2 high-pressure fuel tube flare nuts finger tight at this stage.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.

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Install the new high-pressure fuel pump-to-fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

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

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Install the vacuum pump and the stud bolts.
Torque 89 lb.in (10 Nm)

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NOTE: Make sure that new components are installed.

Install new studs.

Torque 89 lb.in (10 Nm)

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NOTE: Make sure that a new component is installed.

Install a new heat shield and the bolts.

Torque 89 lb.in (10 Nm)

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1. NOTE: Make sure that a new component is installed.
  
  Install the new turbocharger oil supply tube.
2. NOTE: Install all the bolts finger tight before final tightening.
  
  Install the bolts.
  
  Torque 2: 89 lb.in (10 Nm) 3: 89 lb.in (10 Nm)
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1. Install the oil return tube.
2. NOTE: Install all the bolts finger tight before final tightening.
  
  Install the bolts.
  
  Torque 89 lb.in (10 Nm)
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NOTE: Only tighten the nuts and bolts finger tight at this stage.

Install the TC assembly and the fasteners.

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Tighten the fasteners.
Torque 1-4: 168 lb.in (19 Nm) 1-4: 18 lb.ft (24 Nm) 1-4: 18 lb.ft (24 Nm) 5: 89 lb.in (10 Nm) 6: 18 lb.ft (25 Nm)

Fig 10: TC Assembly Bolts Tightening Sequence
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1. Install the coolant hose assembly onto the engine front cover and install the bolts.
  Torque 89 lb.in (10 Nm)
2. Connect the coolant hose assembly to the coolant outlet. Use the General Equipment: Hose Clamp Remover/Installer
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Install the bracket and the fasteners.
Torque Nuts: 53 lb.in (6 Nm) Bolt: 89 lb.in (10 Nm)

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1. Install the coolant hose assembly and the bolts.
  Torque 89 lb.in (10 Nm)
2. Connect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
3. Attach the coolant hose retainers.
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NOTE: Brackets may vary, typical bracket shown.

NOTE: Only tighten the bolts finger tight at this stage.
1. Install the coolant pump and the 2 new bolts.
2. Install the bracket and the remaining coolant pump bolts
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Tighten the bolts in sequence.
Torque 1-5: 89 lb.in (10 Nm) 6-7: Stage 1: 133 lb.in (15 Nm) Stage 2: 90 deg.

Fig 11: Coolant Pump Bolts Tightening Sequence
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Install the accessory drive belt idler pulley and the bolt.
Torque 18 lb.ft (25 Nm)

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Install the generator and the bolts.
Torque 18 lb.ft (25 Nm)

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Install the accessory drive belt tensioner and the bolts.
Torque 18 lb.ft (25 Nm)

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Install the coolant pump pulley and the bolts.
Torque 18 lb.ft (25 Nm)

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Install the engine lifting bracket and the bolts.
Torque 17 lb.ft (23 Nm)

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- Position the vacuum hose assembly onto the engine and attach the retainers.
- Connect the vacuum hoses. Use the General Equipment: Hose Clamp Remover/Installer
- Install the nuts.
  Torque 53 lb.in (6 Nm)
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Install the engine wiring harness and attach the retainers.

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1. Connect the oil pressure switch, the KS.
2. Attach the wiring harness retainers.
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1. Connect the oil control solenoid electrical connector.
2. Attach the wiring harness retainer.
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1. Connect the engine wiring harness electrical connector.
2. Attach the engine wiring harness retainers.
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1. Connect the generator wiring harness terminal.
2. Connect the engine wiring harness electrical connector.
3. Attach the engine wiring harness retainers.
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1. Install the generator nut.
  Torque 159 lb.in (18 Nm)
2. Position the protective cover.
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Attach the wiring harness retainers.

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1. Connect the engine wiring harness electrical connectors.
2. Attach the engine wiring harness retainers.
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1. Install the EVAP canister purge valve and attach the retainers.
2. Connect the quick release coupling. Refer to: Quick Release Coupling .
3. Connect the EVAP canister purge valve electrical connector.
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Install the General Equipment: Lifting BracketInstall the General Equipment: Floor Crane

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Remove the engine from the stand.

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