Section 16 (Engine - 2.5L DURATEC (125KW/170PS)): Assembly: Engine

WARNING: This page is about a different variant/trim than selected.

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal \| TKIT-2009TC-F
Courtesy of FORD MOTOR COMPANY	303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A \| TKIT-2009TC-F
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	303-1416 Tool, Crank Damper Holding \| TKIT-2008ET-FLM
Courtesy of FORD MOTOR COMPANY	303-1417 Tool, Crank Sensor Alignment \| TKIT-2008ET-FLM \| TKIT-2008ET-ROW
Courtesy of FORD MOTOR COMPANY	303-328 (T88P-6701-B1)Replacer, Rear Seal \| TKIT-1988-FLM \| TKIT-1988-F \| TKIT-1988-LM
Courtesy of FORD MOTOR COMPANY	303-465 Tool, Camshaft Align Timing \| TKIT-1994-LMH/MH2 \| TKIT-1994-FH/FMH/FLMH
Courtesy of FORD MOTOR COMPANY	303-507 Timing Peg, Crankshaft TDC \| TKIT-2001N-FLM \| TKIT-2001N-ROW
Mounting Stand
Round-Ended Steel Rule
Piston Ring Compressor

Materials

Name	Specification
Motorcraft® Silicone Gasket RemoverZC-30-A	-
Motorcraft® Metal Surface Prep WipesZC-31-B	-
Motorcraft® Silicone Gasket and SealantTA-30	WSE-M4G323-A4
Motorcraft® Silicone Brake Caliper Grease and Dielectric CompoundXG-3-A	ESE-M1C171-A

NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

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.

NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to the appropriate Engine article.

NOTE: For additional information, refer to the exploded views in DESCRIPTION AND OPERATION .

NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.

NOTE: The front bulkhead does not have an oil squirter.

Install the oil squirters.

Torque:

35 lb.in (4 Nm)

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Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.

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Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.

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Tighten the bolts in sequence shown in 3 stages.
Torque:

Stage 1: 44 lb.in (5 Nm), Stage 2: 18 lb.ft (25 Nm), Stage 3: 90 deg.

Fig 1: Main Bearing Beam Bolts Tightening Sequence
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Measure each crankshaft block main bearing bore diameter.

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Using the chart, select the crankshaft main bearings.

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

Using the original connecting rod cap bolts, install the connecting caps and the bolts. Tighten in 3 stages.

Torque:

Stage 1: 89 lb.in (10 Nm) | Stage 2: 21 lb.ft (29 Nm) | Stage 3: 90 deg.

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Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts.

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Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.

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

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- Remove the bolts in the sequence shown and the main bearing beam.
- Discard the main bearing beam bolts.
Fig 2: Main Bearing Beam Bolts Loosening Sequence
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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: The center bulkhead is the thrust bearing.

Lubricate with clean engine oil and install the upper 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.

Lubricate with clean engine oil and install the lower crankshaft main bearings.

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NOTE: Lubricate the journals on the crankshaft with clean engine oil.

Lubricate with clean engine oil and install the crankshaft.

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Lubricate the main bearing beam with clean engine oil.

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Install the main bearing beam flush.

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NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.

NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

Install the new bolts and tighten in sequence shown in 3 stages.

Torque:

Stage 1: 44 lb.in (5 Nm), Stage 2: 18 lb.ft (25 Nm), Stage 3: 90 deg.

Fig 3: Cylinder Block Bolts Tightening Sequence
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- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- Acceptable crankshaft end play is 0.22-0.45 mm (0.008-0.018 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
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NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

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

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NOTE: The piston compression upper and lower rings should be installed with the paint mark on the outside diameter circumference of the ring to be positioned on the right side of the ring gap. The lower compression ring needs to be installed with the undercut side downward.

NOTE: The upper and lower compression ring end gaps are not controlled for installation.
1. Upper oil control segment ring gap location.
2. Oil control spacer gap location.
3. Lower oil control segment ring end gap.
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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.

Using the Piston Ring Compressor, 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: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.

NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

Install the connecting rod caps and the new bolts. Tighten in 3 stages.

Torque:

Stage 1: 89 lb.in (10 Nm) | Stage 2: 21 lb.ft (29 Nm) | Stage 3: 90 deg.

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NOTE: Only rotate the crankshaft clockwise.
- Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
- Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
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NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

NOTE: The original adjustment shims must be installed in their original positions.

NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.

Install the adjustment shims in their original positions on the seat faces of the balancer unit. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.

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Install the bolts and tighten in sequence shown in 2 stages.
Torque:

Stage 1: 18 lb.ft (25 Nm), Stage 2: 38 lb.ft (52 Nm)

Fig 4: Balancer Unit Bolts Tightening Sequence
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NOTE: Only rotate the crankshaft clockwise.
- Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
- Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
Courtesy of FORD MOTOR COMPANY
NOTE: Only rotate the crankshaft clockwise.
1. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
2. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
3. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
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NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.

NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.

NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown.
- Position as shown. Measure the gear backlash. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
- Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
- Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
- If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. Refer to: Balance Shaft Backlash .
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NOTE: Only rotate the crankshaft clockwise.
1. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
2. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
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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: Clean the oil pump and cylinder block mating surfaces with metal surface prep.

Install the oil pump and the bolts. Tighten in sequence shown in 2 stages.

MaterialMotorcraft® Metal Surface Prep Wipes / ZC-31-B

Torque:

Stage 1: 89 lb.in (10 Nm) | Stage 2: 177 lb.in (20 Nm)

Fig 5: Oil Pump Bolts Tightening Sequence
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Install a new gasket.

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Install the oil pump screen and pickup tube and the bolts.
Torque:

89 lb.in (10 Nm)

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- Using the special tool, position the crankshaft rear oil seal onto the crankshaft. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.
- Install the bolts and the tighten in sequence shown.
  Torque:
  
  89 lb.in (10 Nm)
Fig 6: Crankshaft Rear Oil Seal Bolts Tightening Sequence
Courtesy of FORD MOTOR COMPANY
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

Clean and inspect all mating surfaces of the engine and oil pan.

MaterialMotorcraft® Silicone Gasket Remover / ZC-30-A

MaterialMotorcraft® Metal Surface Prep Wipes / ZC-31-B
NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a 3 mm bead of silicone sealant.

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

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

Install the oil pan and the bolts finger tight.

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Using a straight edge, align the front surface of the oil pan flush with the front surface of the engine block. Use the General Equipment: Round-Ended Steel Rule

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Tighten the bolts in sequence shown.
Torque:

177 lb.in (20 Nm)

Fig 7: Oil Pan Bolts Tightening Sequence
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NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.

MaterialMotorcraft® Metal Surface Prep Wipes / ZC-31-B
NOTE: Dowels must be fully seated in the cylinder block.

Install the cylinder head alignment dowels.

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Apply a 6 mm bead of silicone sealant.
MaterialMotorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

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Install a new cylinder head gasket.

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NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

NOTE: Lubricate the bolts with clean engine oil prior to installation.

Install the cylinder head and the new bolts. Tighten in sequence shown in 5 stages.

Torque:

Stage 1: 62 lb.in (7 Nm), Stage 2: 133 lb.in (15 Nm), Stage 3: 33 lb.ft (45 Nm), Stage 4: 90 deg., Stage 5: 90 deg.

Fig 8: Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR COMPANY
Lubricate with clean engine oil and install the valve tappets.

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NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.

Lubricate the camshafts with clean engine oil and position in the cylinder head.

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- Install the camshaft bearing caps and the bolts finger tight.
- Tighten the bolts in sequence shown in 2 stages.
  Torque:
  
  Stage 1: 62 lb.in (7 Nm), Stage 2: 142 lb.in (16 Nm)
Fig 9: Camshaft Bearing Caps Bolts Tightening Sequence
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Install the VCT oil control solenoid and the bolt.
Torque:

97 lb.in (11 Nm)

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NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

Identify crankshaft sprocket type.
1. Early build engine - Flat faced sprocket (requires diamond washers).
2. Late build engine - Laser etched sprocket (does
  NOT require diamond washers).
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NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.

NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

If equipped, install the diamond washer.

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Install the oil pump sprocket, the chain and the bolt.
Torque:

18 lb.ft (25 Nm)

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1. Install the timing chain tensioner and the shoulder bolts.
  Torque:
  
  89 lb.in (10 Nm)
2. Push the tensioner spring down and position the spring under the shoulder bolt.
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NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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

Install the camshaft sprockets and the bolts.

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Install the timing chain guide and the bolts.
Torque:

89 lb.in (10 Nm)

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Install the timing chain.

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Install the timing chain tensioner arm.

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NOTE: If equipped with aluminum timing chain tensioner.

NOTE: If the timing chain tensioner plunger is not pinned in the compressed position, follow the next step.
Reset the timing chain tensioner.
1. Position the timing chain tensioner in a soft-jawed vise.
2. Spread the ends of the ratchet wire clip apart.
3. Using the soft-jawed vise, compress the plunger to the reset position.
4. Install a locking pin in the 2 holes of the timing chain tensioner body to hold the plunger in place.
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NOTE: If equipped with aluminum timing chain tensioner.

NOTE: Do not remove the locking pin until the tensioner bolts are tightened.
1. Install the timing chain tensioner and the bolts.
  Torque:
  
  89 lb.in (10 Nm)
2. Remove the locking pin.
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NOTE: If equipped with cast iron timing chain tensioner.

NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.

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Using a small pick, push back and hold the ratchet mechanism.

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While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

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Install a locking pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

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NOTE: If equipped with cast iron timing chain tensioner.

NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

Install the timing chain tensioner and the bolts.

Torque:

89 lb.in (10 Nm)

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NOTE: If equipped with cast iron timing chain tensioner.

Remove the locking pin.

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NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: Use the flats on the camshafts to prevent camshaft rotation.

Tighten the camshaft sprocket bolts in 2 stages.

Torque:

Stage 1: 30 lb.ft (40 Nm) | Stage 2: 60 deg.

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NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the mounting surfaces of the engine and the front cover.

MaterialMotorcraft® Silicone Gasket Remover / ZC-30-A

MaterialMotorcraft® Metal Surface Prep Wipes / ZC-31-B
NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.

Apply a 15 mm bead of silicone sealant to the cylinder head and oil pan joint areas.

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

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NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.

Apply a 3 mm bead of silicone sealant to the outside sealing surfaces of the engine front cover. Apply a 2 mm bead of silicone sealant to the inside sealing surfaces.

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

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Install the engine front cover and the bolts. Tighten in sequence shown.
Torque:

Bolts 1 - 3: 35 lb.ft (48 Nm) Bolts 4 - 12: 89 lb.in (10 Nm) Bolt 13: 35 lb.ft (48 Nm) Bolts 14 - 22: 89 lb.in (10 Nm)

Fig 10: Engine Front Cover Bolts Tightening Sequence
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NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

Lubricate with clean engine oil and using the special tool, install the crankshaft front oil seal. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.

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NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.

NOTE: Early build engines are equipped with a diamond washers on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

If equipped, install the diamond washer onto the crankshaft.

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NOTE: Apply clean engine oil on the seal before installing.

NOTE: Do not install the crankshaft pulley bolt at this time.

Position the crankshaft pulley onto the crankshaft with the pulley at the 6 o'clock position.

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NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install a standard M6 X 18 mm bolt through the crankshaft pulley and thread it onto the engine front cover.

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NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

NOTE: Install a new crankshaft pulley bolt.

Using the special tool, tighten the crankshaft pulley bolt in 2 stages. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.

Torque:

Stage 1: 74 lb.ft (100 Nm) | Stage 2: 90 deg.

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Remove the standard M6 X 18 mm bolt.

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Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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NOTE: Only turn the engine in the normal direction of rotation.

Rotate the crankshaft clockwise one and three-fourth turns.

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NOTE: Only rotate the crankshaft clockwise.
- Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
- Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
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NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

Install a standard M6 X 18 mm bolt. Check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected.

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If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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

Install the CKP sensor and the bolts.

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Install the special tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Use Special Service Tool: 303-1417 Tool, Crank Sensor Alignment.
Torque:

62 lb.in (7 Nm)

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Remove the standard M6 X 18 mm bolt.

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Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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Install the engine plug bolt.
Torque:

177 lb.in (20 Nm)

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NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean the valve cover gasket surfaces.

MaterialMotorcraft® Metal Surface Prep Wipes / ZC-31-B
NOTE: Installation of a new VCT solenoid seal is required if a damaged seal was removed during disassembly of the engine.

Using the special tools, install the VCT oil control solenoid seal. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer., 205-153 (T80T-4000-W) Handle.

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Inspect and if necessary, install new valve cover gaskets.

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Apply a 6 mm bead of silicone sealant.
MaterialMotorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

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NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

Install the valve cover and tighten the fasteners in sequence shown.

Torque:

89 lb.in (10 Nm)

Fig 11: Valve Cover Fasteners Tightening Sequence
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Inspect the ignition coil-on-plug boots for cracks, rips, or tears. Replace any damaged coil-on-plug boots.

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NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

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

MaterialMotorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

Torque:

71 lb.in (8 Nm)

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Install the oil level indicator.

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If equipped.
- Install the block heater.
  Torque:
  
  30 lb.ft (40 Nm)
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Inspect the crankcase vent oil separator gasket and replace if necessary.

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Install the crankcase vent oil separator and the bolts.
Torque:

89 lb.in (10 Nm)

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NOTE: The KS must not touch the crankcase vent oil separator.

Install the KS and the bolt.

Torque:

177 lb.in (20 Nm)

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Install the coolant by pass hose and connect the clamps.

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Install the EGR tube.
Torque:

41 lb.ft (55 Nm)

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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.

Inspect the intake manifold gaskets and replace if necessary.

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Position the intake manifold and connect the crankcase vent oil separator tube.

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Position back the intake manifold and install the bolts. Tighten the bolts in sequence shown.
Torque:

159 lb.in (18 Nm)

Fig 12: Intake Manifold Bolts Tightening Sequence
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NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

Install the fuel injector retaining clips and the fuel injector O-ring seals. Lubricate the fuel injector O-ring seals.

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Install the fuel injectors into the fuel rail.

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Install the fuel rail assembly and the bolts.
Torque:

17 lb.ft (23 Nm)

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Install the radio capacitor and the nut.
Torque:

89 lb.in (10 Nm)

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Install the fuel rail insulator.

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Install the engine wire harness and attach the wire harness retainer.

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Connect the EGR valve electrical connector.

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Position the bracket and install the nuts.
Torque:

80 lb.in (9 Nm)

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Attach the wire harness retainers and connect the MAP sensor electrical connector.

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Connect the TB (throttle body) and EVAP canister purge valve electrical connectors.

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Attach the wire harness retainer onto the intake manifold.

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Attach the wire harness retainers onto the fuel rail and connect the fuel injector electrical connectors.

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Attach the wire harness retainer and connect the electrical connector.

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Connect the CHT sensor electrical connector and position back the boot.

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Connect the CMP sensor and ignition coil-on-plugs electrical connectors.

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Connect the VCT oil control solenoid electrical connector.

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Connect the electrical connector and wire retainers to the intake manifold.

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Attach the wire harness retainers.

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Attach the wire harness retainer and connect the CKP sensor electrical connector.

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Install the crankcase vent tube. Refer to: Quick Release Coupling .

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NOTE: Clean the gasket mating surface with metal surface prep.

Install a new gasket.

MaterialMotorcraft® Metal Surface Prep Wipes / ZC-31-B

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Install the oil filter adapter and the bolts.
Torque:

18 lb.ft (25 Nm)

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Connect the EOP switch electrical connector.

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Inspect the thermostat housing gasket and replace if necessary.

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Install the thermostat housing and the bolts.
Torque:

89 lb.in (10 Nm)

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NOTE: Clean the coolant pump mating surfaces.

NOTE: Lubricate the new coolant pump O-ring seal with engine coolant.

Install the coolant pump and the bolts.

MaterialMotorcraft® Metal Surface Prep Wipes / ZC-31-B

Torque:

89 lb.in (10 Nm)

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Install the coolant pump pulley and the bolts.
Torque:

177 lb.in (20 Nm)

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Install the idler pulley and the bolt.
Torque:

97 lb.in (11 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 bracket, the stud bolt
Torque:

18 lb.ft (25 Nm)

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General Equipment: Spreader Bar Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

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Remove the engine from the mounting stand. Use the General Equipment: Mounting Stand

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NOTE: Special bolts are used for installation. Do not use standard bolts.
- Install the flexplate and the new bolts. Tighten in sequence shown in 3 stages.
  Torque:
  
  Stage 1: 37 lb.ft (50 Nm), Stage 2: 59 lb.ft (80 Nm), Stage 3: 83 lb.ft (112 Nm)
- Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

Fig 13: Flexplate Bolts Tightening Sequence

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