Section 2 (Engine - 2.7L ECOBOOST (238KW/324PS)): Assembly: Engine

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

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar | TKIT-2006UF-FLM | TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer | TKIT-2006UF-FLM | TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1248 Camshaft holding tools | TKIT-2006UF-FLM | TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1250 Seal Installer, Rear Main | TKIT-2006UFFLM
Courtesy of FORD MOTOR COMPANY	303-1531 Installer, Front Crank Seal and Damper
Courtesy of FORD MOTOR COMPANY	303-1633 Remover, Roller Rocker Follower | TKIT-2014D-ROW3 | TKIT-2014D-FL_ROW
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2) | TKIT-2014D-ROW3 | TKIT-2014D-FL_ROW
Courtesy of FORD MOTOR COMPANY	303-335 (T88T-6701-A) Installer, Front Cover Oil Seal | TKIT-1988-FLM | TKIT-1988-F
Floor Crane
Mounting Stand
Hose Clamp Remover/Installer
Flat-Bladed Screwdriver
Piston Ring Compressor
Vise
Vise Jaw Protectors

Materials 

1. Read and record the four character code on the cylinder block. The first letter is the code for main No. 1, the second letter for main No. 2, the third letter for main No. 3 and the fourth letter for main No. 4.

   Courtesy of FORD MOTOR COMPANY

2. Read and record the four character code on the crankshaft face. The first letter is the code for main No. 1, the second letter for main No. 2, the third letter for main No. 3 and the fourth letter for main No. 4.

   Courtesy of FORD MOTOR COMPANY

3. Using the data recorded earlier and the Bearing Select Fit Chart, determine the required bearing grade for the main bearings.
   1. Look at the bearing select fit chart and for each main, match the block and crankshaft code with its corresponding column or row by reading across the crankshaft row and down the block column to select the proper grade bearings for each main.
   2. For example, if the block code is GLMD and the crankshaft code is PNLO, main No. 1 should be assembled with grade 2 upper and lower bearings, as determined by the intersection of the

      G  block column and the

      P  crankshaft row. Main No. 2 should be assembled with grade 3 upper and lower bearings. Main No. 3 should be assembled with grade 3 upper and grade 4 lower bearings. Main No. 4 should be assembled with grade 2 upper and lower bearings.

   Courtesy of FORD MOTOR COMPANY

4. Install the piston cooling jets and bolts into the cylinder block.

   Torque: 89 lb.in (10 Nm)

   Courtesy of FORD MOTOR COMPANY

5. Install the crankshaft main bearings.
   • Install the crankshaft upper main bearings and thrust bearing into the cylinder block.
   • Install the crankshaft lower main bearings into the bearing caps.
   • Make sure all oil passages are aligned.
   • Lubricate all main bearings with clean engine oil.

   Courtesy of FORD MOTOR COMPANY

6. NOTE: Lubricate the crankshaft bearing journals with clean engine oil.

   Install the crankshaft into the cylinder block.

   Courtesy of FORD MOTOR COMPANY

7. Install the No. 1, 2 and 3 main bearing caps and bolts on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the cap bolts.

   Courtesy of FORD MOTOR COMPANY

8. NOTE: Lubricate the lower thrust washer with clean engine oil.

   Install the lower thrust washer and the No. 4 main bearing cap and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap bolts.

   Courtesy of FORD MOTOR COMPANY

9. Push the crankshaft forward to seat the crankshaft thrust washer.

   Courtesy of FORD MOTOR COMPANY

10. Tighten the main bearing cap bolts.

    Torque: Stage 1: 30 lb.ft (40 Nm) | Stage 2: Loosen: 360° | Stage 3: 26 lb.ft (35 Nm) | Stage 4: 180°

    Fig 1: Main Bearing Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
11. • Check the crankshaft end play. Refer to: Specifications .
    • Check the piston-to-cylinder block and piston ring clearances. Refer to: Specifications .
    • Assemble the pistons and position the piston ring gaps. Refer to: Specifications .

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

    Courtesy of FORD MOTOR COMPANY

13. Courtesy of FORD MOTOR COMPANY

    1. For assembly purposes the bump on the connecting rod will face the same way as the bump on the connecting rod cap.

14. 1. For assembly purposes the bowl on the dome of the piston should be facing toward the intake of the engine.
    2. On the RH bank the bump on the connecting rod should face the front of the engine.
    3. On the LH bank the bump on the connecting rod should face the rear of the engine.

    Courtesy of FORD MOTOR COMPANY

15. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
    NOTE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.
    NOTE: Lubricate the piston with clean engine oil.
    • Position the piston assembly and piston ring installer into the cylinder. Use the General Equipment: Piston Ring Compressor
    • NOTE: A commercially available piston rod installer must be used to prevent damage to the crankshaft journal.

      Install a piston rod installer over the crankshaft journal and into the bolt holes of the connecting rod.

    • Push the piston into the cylinder bore and guide the connecting rod onto the crankshaft journal.

    Courtesy of FORD MOTOR COMPANY

16. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
    1. Install the connecting rod cap and bearing.

       Torque: Stage 1: 24 lb.ft (32 Nm) | Stage 2: Loosen: 180° | Stage 3: 24 lb.ft (32 Nm) | Stage 4: 90°

    2. Repeat the steps for each of the remaining pistons.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

18. NOTE: If the engine block skirt stiffener is not installed, aligned and the bolts tightened to minimum specification within 10 minutes, the sealant must be removed and the sealing area cleaned.
    1. Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan sealing surfaces of the inner bosses.

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

    2. Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the chamfer of the oil pan sealing surfaces.

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

       Torque: Stage 1: 35 lb.in (4 Nm) | Stage 2: Loosen: 360°

    Courtesy of FORD MOTOR COMPANY

21. 1. Using a straight edge, align the rear face of the engine block skirt stiffener to the rear face of the engine block, flush or up to 0.250 mm (0.01 in) underflush.
    2. Using a straight edge, align the machined bosses on the left side of the engine block skirt stiffener to the machined bosses on the left side of the engine block flush or within 0.280 mm (0.011 in) of flush.

    Courtesy of FORD MOTOR COMPANY

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

    Tighten the engine block skirt stiffener bolts.

    Torque: Stage 1: 35 lb.in (4 Nm) | Stage 2: 18 lb.ft (24 Nm)

    Courtesy of FORD MOTOR COMPANY

23. If equipped, install the block heater.

    Torque: 41 lb.ft (55 Nm)

    Courtesy of FORD MOTOR COMPANY

24. NOTE: Do not reuse the ECT sensor, install a new sensor.

    Install a new ECT sensor.

    Torque: 20 lb.ft (27 Nm)

    Courtesy of FORD MOTOR COMPANY

25. 1. Install the KS assembly and the bolts.

       Torque: 97 lb.in (11 Nm)

    2. Connect the ECT sensor electrical connector.

    Courtesy of FORD MOTOR COMPANY

26. Inspect the coolant outlet connector pipe gasket and replace if damaged.

    Courtesy of FORD MOTOR COMPANY

27. 1. Install the coolant outlet connector pipe, the bolts and the stud bolt.

       Torque: 89 lb.in (10 Nm)

    2. Attach the wiring harness retainer to the stud bolt.

    Courtesy of FORD MOTOR COMPANY

28. NOTE: Rotate the crankshaft utilizing only the original crankshaft pulley bolt. Failure to follow this direction may cause damage to the crankshaft and result in engine failure.

    Install the original crankshaft pulley bolt and rotate the crankshaft clockwise until the keyway is at the 9 o'clock position.

    Courtesy of FORD MOTOR COMPANY

29. Install a new cylinder head gasket.

    Courtesy of FORD MOTOR COMPANY

30. • Install the cylinder head.
    • Install new cylinder head bolts.

      Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: Loosen: 2 turn(s) | Stage 3: 37 lb.ft (50 Nm) | Stage 4: 180°

    Courtesy of FORD MOTOR COMPANY

31. Inspect the O-ring and replace if necessary.

    Courtesy of FORD MOTOR COMPANY

32. 1. Install the cylinder head to coolant outlet connector hose assembly and the bolt.

       Torque: 89 lb.in (10 Nm)

    2. Connect the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

33. NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure.
    NOTE: If the original components are to be reinstalled, they must be installed in their original locations.
    1. Lubricate the hydraulic lash adjusters with clean engine oil.
    2. Install the hydraulic lash adjusters.

    Courtesy of FORD MOTOR COMPANY

34. NOTE: It is not necessary to position the scarf-cut seal ends when installing the camshafts.
    1. Lubricate the camshafts with clean engine oil prior to installation.
    2. Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

    Courtesy of FORD MOTOR COMPANY

35. Apply a 1 mm bead of sealant to the rear camshaft cap mounting surface of the cylinder head.

    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    Courtesy of FORD MOTOR COMPANY

36. Install the camshaft bearing caps and the bolts. Do not tighten at this time.

    Courtesy of FORD MOTOR COMPANY

37. Install the front camshaft bearing mega cap and the bolts. Do not tighten at this time.

    Courtesy of FORD MOTOR COMPANY

38. Tighten the bolts in sequence.

    Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

39. NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For installation of the LH side the circle marks are used.
    1. Install the VCT units. The circle  timing marks on the VCT units will be at the 10 o'clock (intake) and 12:30 (exhaust) positions as shown in the illustration. Install Special Service Tool: 303-1248 Camshaft holding tools.
    2. Install the new VCT unit bolts.

       Torque: Stage 1: 30 lb.ft (40 Nm) | Stage 2: Loosen: 360° | Stage 3: 37 lb.ft (50 Nm) | Stage 4: 90°

    3. Remove Special Service Tool: 303-1248 Camshaft holding tools.

    Courtesy of FORD MOTOR COMPANY

40. Install a new cylinder head gasket.

    Courtesy of FORD MOTOR COMPANY

41. • Install the cylinder head.
    • Install new cylinder head bolts.

      Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: Loosen: 2 turn(s) | Stage 3: 37 lb.ft (50 Nm) | Stage 4: 180°

    Courtesy of FORD MOTOR COMPANY

42. NOTE: Make sure that a new high-pressure fuel tube is installed.
    1. Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas below.

       Courtesy of FORD MOTOR COMPANY

    2. NOTE: In stage 3, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 55 lb.ft (75 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.

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

       Torque: Stage 1: Tighten to : 62 lb.in (7 Nm) | Stage 2: Tighten to : 89 lb.in (10 Nm) | Stage 3: Tighten an additional : 30°

    Courtesy of FORD MOTOR COMPANY

43. Inspect the O-ring and replace if necessary.

    Courtesy of FORD MOTOR COMPANY

44. 1. Install the cylinder head to coolant outlet connector hose assembly and the bolt.

       Torque: 89 lb.in (10 Nm)

    2. Connect the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

45. NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure.
    NOTE: If the original components are to be reinstalled, they must be installed in their original locations.
    1. Lubricate the hydraulic lash adjusters with clean engine oil.
    2. Install the hydraulic lash adjusters.

    Courtesy of FORD MOTOR COMPANY

46. NOTE: It is not necessary to position the scarf-cut seal ends when installing the camshafts.
    • Lubricate the camshafts with clean engine oil prior to installation.
    • Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

    Courtesy of FORD MOTOR COMPANY

47. Apply a 1 mm bead of sealant to the rear camshaft cap mounting surface of the cylinder head.

    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    Courtesy of FORD MOTOR COMPANY

48. Install the camshaft bearing caps and the bolts. Do not tighten at this time.

    Courtesy of FORD MOTOR COMPANY

49. Install the front camshaft bearing mega cap and the bolts. Do not tighten at this time.

    Courtesy of FORD MOTOR COMPANY

50. Tighten the bolts in sequence.

    Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

51. NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For installation of the RH side the triangle marks are used.
    1. Install the VCT units. The triangle  timing marks on the VCT units will be at the 2 o'clock (intake) and 11 o'clock (exhaust) positions as shown in the illustration. Install Special Service Tool: 303-1248 Camshaft holding tools.
    2. Install the new VCT unit bolts.

       Torque: Stage 1: 30 lb.ft (40 Nm) | Stage 2: Loosen: 360° | Stage 3: 37 lb.ft (50 Nm) | Stage 4: 90°

    3. Remove Special Service Tool: 303-1248 Camshaft holding tools.

    Courtesy of FORD MOTOR COMPANY

52. Using the original crankshaft pulley bolt, rotate the crankshaft clockwise until the keyway is at the 11 o'clock position.
    • Remove the crankshaft pulley bolt.

    Courtesy of FORD MOTOR COMPANY

53. Install the timing chain sprocket.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

55. Install the LH timing chain guide and bolts.

    Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

56. Install the LH timing chain tensioner arm.

    Courtesy of FORD MOTOR COMPANY

57. Slide the tensioner cylinder out of the LH timing chain tensioner housing.

    Courtesy of FORD MOTOR COMPANY

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

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

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

60. 1. Firmly press the tensioner cylinder into the tensioner housing until the shoulder of the tensioner cylinder is approximately 3 mm (0.125 in) below the top of the housing.
    2. Install a retaining pin into the hole in the housing to lock the tensioner cylinder in the retracted position.

    Courtesy of FORD MOTOR COMPANY

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

       Torque: 89 lb.in (10 Nm)

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

    Courtesy of FORD MOTOR COMPANY

62. Install the crankshaft sprocket.

    Courtesy of FORD MOTOR COMPANY

63. Install the oil pump drive belt onto the crankshaft sprocket.

    Courtesy of FORD MOTOR COMPANY

64. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
65. NOTE: Make sure the oil pump drive belt teeth are engaged in the crankshaft sprocket prior to installing the oil pump.
    1. Install the oil pump sprocket into the oil pump drive belt.
    2. Raise the rear of the oil pump assembly into the installed position.
    3. Install the oil pump bolts.

       Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

    Courtesy of FORD MOTOR COMPANY

66. Install a new oil pump pickup O-ring seal.

    Courtesy of FORD MOTOR COMPANY

67. Install the oil pump pickup and bolts.

    Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

    Courtesy of FORD MOTOR COMPANY

68. Install the original crankshaft pulley bolt.

    Courtesy of FORD MOTOR COMPANY

69. NOTE: The crankshaft must be rotated clockwise one revolution (360 degrees). Failure to do so will result in incorrect camshaft timing.
    1. Rotate the crankshaft clockwise one revolution (360 degrees).
    2. Position the crankshaft sprocket keyway at the 11 o'clock position.

    Courtesy of FORD MOTOR COMPANY

70. Remove and discard the original crankshaft pulley bolt.

    Courtesy of FORD MOTOR COMPANY

71. Install the timing chain sprocket.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

73. Install the RH timing chain guide and bolts.

    Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

74. Install the RH timing chain tensioner arm.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

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

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

78. 1. Firmly press the tensioner cylinder into the tensioner housing until the shoulder of the tensioner cylinder is approximately 3 mm (0.125 in) below the top of the housing.
    2. Install a retaining pin into the hole in the housing to lock the tensioner cylinder in the retracted position.

    Courtesy of FORD MOTOR COMPANY

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

       Torque: 89 lb.in (10 Nm)

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

82. Install new engine front cover gaskets.

    Courtesy of FORD MOTOR COMPANY

83. NOTE: The engine oil gallery seal (6G068) is asymmetrical and must be installed exactly as shown or damage to the engine may occur.
    1. Lubricate the new oil gallery seal (6G068) with clean engine oil.
    2. Install the new oil gallery seal (6G068) with the squared edge toward the engine block.

    Courtesy of FORD MOTOR COMPANY

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

    Apply 9 mm (0.35 in) beads of Motorcraft® High Performance Engine RTV Silicone 10 mm (0.40 in) in length to the cylinder block skirt-to-cylinder block joints and the cylinder head-to-cylinder block joints as indicated.

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

    Courtesy of FORD MOTOR COMPANY

85. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.
    1. Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces of the inner bolt bosses.

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

    2. Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the chamfer of the engine front cover sealing surfaces.

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

    Courtesy of FORD MOTOR COMPANY

86. 1. Install the engine front cover and install the fasteners finger tight.
    2. Tighten bolts 12 through 13.

       Torque: Stage 1: 22 lb.ft (30 Nm) | Stage 2: 45°

    3. Tighten bolts 1 through 11.

       Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 45°

    4. Tighten bolts 14 through 16.

       Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 60°

    5. Tighten bolts 15 through 20.

       Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 45°

    Courtesy of FORD MOTOR COMPANY

87. Lubricate the engine front cover bore with clean engine oil.

    Courtesy of FORD MOTOR COMPANY

88. Using the special tools, install the new crankshaft front oil seal. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal, 303-1531 Installer, Front Crank Seal and Damper.

    Courtesy of FORD MOTOR COMPANY

89. NOTE: The outer pulley must be removed to properly hold the pulley during the crankshaft bolt tightening step.

    Remove the bolts and the outer pulley,

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

91. Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal, 303-1531 Installer, Front Crank Seal and Damper.

    Courtesy of FORD MOTOR COMPANY

92. NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).
    NOTE: The aid of an assistant is required to perform this step.

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

    Torque: Stage 1: 166 lb.ft (225 Nm) | Stage 2: Loosen: 360° | Stage 3: 26 lb.ft (35 Nm) | Stage 4: 270°

    Courtesy of FORD MOTOR COMPANY

93. Install the outer pulley and bolts.

    Torque: 26 lb.ft (35 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

95. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
    NOTE: It may be necessary to push the valve down while compressing the spring.
    1. Install Special Service Tool: 303-1633 Remover, Roller Rocker Follower.
    2. Turn the knob on the special tool clockwise to depress the valve and spring.

    Courtesy of FORD MOTOR COMPANY

96. NOTE: Component(s) must be lubricated with clean engine oil.
    1. Lubricate the camshaft roller follower with clean engine oil.
    2. Position the camshaft roller follower and engage the clip onto the hydraulic lash adjuster.
    3. Turn the knob on the special tool counterclockwise to raise the valve and spring.
    4. Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower.
    • Repeat the necessary steps to install the remaining camshaft roller followers.

    Courtesy of FORD MOTOR COMPANY

97. Install new gaskets.

    Courtesy of FORD MOTOR COMPANY

98. Make sure that the mating faces are clean and free of foreign material.

    Courtesy of FORD MOTOR COMPANY

99. Apply 8 mm diameter drops of sealant in the locations shown.

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

    Courtesy of FORD MOTOR COMPANY

100. Install the cover and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

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

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

     Courtesy of FORD MOTOR COMPANY

102. Install new gaskets.

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

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

     Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the locations shown.

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

     Courtesy of FORD MOTOR COMPANY

105. Install the valve cover and tighten the bolts in sequence.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

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

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

     Courtesy of FORD MOTOR COMPANY

107. Install a new gasket.

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

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

     Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the locations shown.

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

     Courtesy of FORD MOTOR COMPANY

110. Install the valve cover and tighten the bolts in sequence.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

111. Install the bracket and nut.

     Torque: 55 lb.in (6.2 Nm)

     Courtesy of FORD MOTOR COMPANY

112. Make sure that the mating faces are clean and free of foreign material.

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

114. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
     NOTE: The oil pan must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 minutes of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.
     1. Install a new oil pan press-in-place gasket.
     2. Apply a 18 mm (0.708 in) drop of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder block joint areas on the oil pan.

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

     Courtesy of FORD MOTOR COMPANY

115. Install the oil pan and the bolts.

     Torque: Stage 1: 31 lb.in (3.5 Nm) | Stage 2: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

116. If the turbocharger coolant supply tube was removed from the turbocharger, then install a new O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

     Courtesy of FORD MOTOR COMPANY

117. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. If removed, install the turbocharger coolant supply tube to the turbocharger, then install and tighten the turbocharger coolant supply tube bolt.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

118. If removed, install and tighten the turbocharger mounting studs.

     Torque: 106 lb.in (12 Nm)

     Courtesy of FORD MOTOR COMPANY

119. Install the new turbocharger gasket.

     Courtesy of FORD MOTOR COMPANY

120. Install a new O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

     Courtesy of FORD MOTOR COMPANY

121. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. Install the turbocharger coolant supply tube to the engine block while installing the turbocharger. Loosely install the turbocharger retainers. Tighten the turbocharger retainers in the following 3 stages, in the sequence shown.

        Torque: Tighten 1 to : 89 lb.in (10 Nm) Tighten 2 to : 177 lb.in (20 Nm) Tighten 3 to : 177 lb.in (20 Nm) Tighten 1 to : 44 lb.ft (60 Nm) Tighten 2 to : 44 lb.ft (60 Nm) Tighten 3 to : 27 lb.ft (37 Nm) Re-tighten 1 to : 44 lb.ft (60 Nm) Re-tighten 2 to : 44 lb.ft (60 Nm) Re-tighten 3 to : 27 lb.ft (37 Nm)

     Courtesy of FORD MOTOR COMPANY

122. Install and tighten the turbocharger coolant supply tube bolt.

     Torque: 18 lb.ft (24 Nm)

     Courtesy of FORD MOTOR COMPANY

123. Install the new turbocharger oil return tube-to-engine block gasket.

     Courtesy of FORD MOTOR COMPANY

124. Install a new O-ring seal, then lubricate with clean engine oil.

     Courtesy of FORD MOTOR COMPANY

125. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

126. NOTE: A new turbocharger oil supply tube filter must be installed. Failure to install a new filter will cause turbocharger failure.

     Install the new O-ring seals and the new turbocharger oil supply tube oil filter. Lubricate the new O-ring seals with clean engine oil.

     Courtesy of FORD MOTOR COMPANY

127. NOTE: When installing the turbocharger oil supply tube into the engine block, use care not to damage the new turbocharger oil supply tube oil filter.
     1. NOTE: Do not use a metal brush; damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore and the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. Install the turbocharger oil supply tube, then install and tighten the turbocharger oil supply tube bolts.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

128. Install a new turbocharger coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

     Courtesy of FORD MOTOR COMPANY

129. 1. Install the turbocharger coolant return tube and clamp. Use the General Equipment: Hose Clamp Remover/Installer
     2. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     3. Install the turbocharger coolant return tube to the turbocharger, then install and tighten the turbocharger coolant return tube bolt.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

130. If the turbocharger coolant supply tube was removed from the turbocharger, then install a new O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

     Courtesy of FORD MOTOR COMPANY

131. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. If removed, install the turbocharger coolant supply tube to the turbocharger, then install and tighten the turbocharger coolant supply tube bolt.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

132. If removed, install and tighten the turbocharger mounting studs.

     Torque: 106 lb.in (12 Nm)

     Courtesy of FORD MOTOR COMPANY

133. Install the new turbocharger gasket.

     Courtesy of FORD MOTOR COMPANY

134. Install a new O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

     Courtesy of FORD MOTOR COMPANY

135. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. Install the turbocharger coolant supply tube to the engine block while installing the turbocharger. Loosely install the turbocharger retainers. Tighten the turbocharger retainers in the following 3 stages, in the sequence shown.

        Torque: Tighten 1 to : 89 lb.in (10 Nm) Tighten 2 to : 177 lb.in (20 Nm) Tighten 3 to : 177 lb.in (20 Nm) Tighten 1 to : 44 lb.ft (60 Nm) Tighten 2 to : 44 lb.ft (60 Nm) Tighten 3 to : 27 lb.ft (37 Nm) Re-tighten 1 to : 44 lb.ft (60 Nm) Re-tighten 2 to : 44 lb.ft (60 Nm) Re-tighten 3 to : 27 lb.ft (37 Nm)

     Courtesy of FORD MOTOR COMPANY

136. Install and tighten the turbocharger coolant supply tube bolt.

     Torque: 18 lb.ft (24 Nm)

     Courtesy of FORD MOTOR COMPANY

137. Install the new turbocharger oil return tube-to-engine block gasket.

     Courtesy of FORD MOTOR COMPANY

138. Install a new O-ring seal, then lubricate with clean engine oil.

     Courtesy of FORD MOTOR COMPANY

139. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

140. NOTE: A new turbocharger oil supply tube filter must be installed. Failure to install a new filter will cause turbocharger failure.

     Install the new O-ring seals and the new turbocharger oil supply tube oil filter. Lubricate the new O-ring seals with clean engine oil.

     Courtesy of FORD MOTOR COMPANY

141. 1. NOTE: Do not use a metal brush; damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore and the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. Install the turbocharger oil supply tube, then loosely install the bolt.

     Courtesy of FORD MOTOR COMPANY

142. Connect the turbocharger oil supply tube to the turbocharger, then install and tighten the bolt.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

143. Tighten the turbocharger oil supply tube bolt.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

144. Install a new turbocharger coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

     Courtesy of FORD MOTOR COMPANY

145. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

        Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     2. Install and connect the turbocharger coolant return tube and clamp, then install and tighten the turbocharger coolant return tube bolt. Use the General Equipment: Hose Clamp Remover/Installer

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

146. Install a new coolant pump gasket.

     Courtesy of FORD MOTOR COMPANY

147. 1. Lubricate the inside and the outside diameter of the grommet with clean engine coolant.
     2. Install the grommet so it is flush with the rear of the coolant pump housing.

     Courtesy of FORD MOTOR COMPANY

148. NOTE: Verify the front cover dowel pins are aligned to the coolant pump and that the coolant pump is fully seated prior to installing the fasteners.
     • Install the coolant pump and the bolts.

       Torque: Fasteners 1-6: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

     • Torque:

       Fastener 7: 18 lb.ft (24 Nm)

     • Torque:

       Fastener 8: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

     Courtesy of FORD MOTOR COMPANY

149. 1. Lubricate the new EGR cooler O-ring seals with clean engine oil.
     2. Install the EGR cooler and the bolts.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

150. Install a new EGR tube gasket.

     Courtesy of FORD MOTOR COMPANY

151. Install a new EGR tube gasket.

     Courtesy of FORD MOTOR COMPANY

152. Install the EGR tube, the nuts and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

153. Inspect the high-pressure fuel pump drive unit gasket and replace if damaged.

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

155. Apply 8 mm dots of sealant to the camshaft bearing cap and cylinder head seam as shown.

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

     Courtesy of FORD MOTOR COMPANY

156. Install the high-pressure fuel pump drive unit and stud bolts.

     Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 45°

     Courtesy of FORD MOTOR COMPANY

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

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

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

159. NOTE: The roller tappets roller goes down towards the camshaft.
     NOTE: Align the notch on the high-pressure fuel pump tappet and with the groove in the high-pressure fuel pump drive unit bore.

     Install the high-pressure fuel pump tappet.

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

161. Install the high-pressure fuel pump, then install and finger tighten the high-pressure fuel pump nuts. Alternately tighten each of the high-pressure fuel pump nuts one complete revolution until seated. Then tighten the fuel high-pressure fuel pump nuts in the following 2 stages.

     Torque: Stage 1: Tighten to : 177 lb.in (20 Nm) | Stage 2: Tighten an additional : 45°

     Courtesy of FORD MOTOR COMPANY

162. NOTE: Make sure that a new high-pressure fuel tube is installed.
     1. Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas below.

        Courtesy of FORD MOTOR COMPANY

     2. Install the high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following stages.

        Torque: Stage 1: Tighten to : 62 lb.in (7 Nm) | Stage 2: Tighten to : 22 lb.ft (30 Nm)

     Courtesy of FORD MOTOR COMPANY

163. Install the fuel supply manifold and the stud bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

164. 1. Attach the wiring harness retainers.
     2. Connect the fuel supply quick connect coupling. Refer to: Quick Release Coupling .

     Courtesy of FORD MOTOR COMPANY

165. Connect the quick release couplings. Refer to: Quick Release Coupling .

     Courtesy of FORD MOTOR COMPANY

166. Install the high pressure fuel pump shield and the stud bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

167. Install the engine wiring harness onto the engine.
     • Connect the engine wiring harness electrical connectors.

     Courtesy of FORD MOTOR COMPANY

168. 1. Connect the engine wiring harness electrical connectors.
     2. Attach the engine wiring harness retainers.

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

170. 1. Install the ignition coils and the stud bolts.

        Torque: 53 lb.in (6 Nm)

     2. Attach the engine wiring harness retainers.
     3. Connect the ignition coil-on-plugs electrical connectors.

     Courtesy of FORD MOTOR COMPANY

171. 1. Connect the fuel pump electrical connector.
     2. Attach the wiring harness retainers.
     3. Install the wiring harness ground terminal and the stud bolt.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

172. 1. Connect the wastegate control actuator and oil pressure sensor electrical connectors.
     2. Attach the engine wiring harness retainers.

     Courtesy of FORD MOTOR COMPANY

173. Connect the oil control solenoid electrical connector and attach the wiring harness retainers.

     Courtesy of FORD MOTOR COMPANY

174. 1. Connect the engine wiring harness electrical connectors.
     2. Attach the engine wiring harness retainers.

     Courtesy of FORD MOTOR COMPANY

175. 1. Connect the wastegate control actuator electrical connector.
     2. Attach the engine wiring harness retainer.
     3. Connect the CHT sensor electrical connector.
     4. Slide the insulator down over the CHT connector.

     Courtesy of FORD MOTOR COMPANY

176. 1. Install the ignition coils and the stud bolts.

        Torque: 53 lb.in (6 Nm)

     2. Attach the engine wiring harness retainers.
     3. Connect the ignition coil-on-plugs electrical connectors.

     Courtesy of FORD MOTOR COMPANY

177. 1. Connect the KS wiring harness connector.
     2. Install the ground wire and the bolt.

        Torque: 89 lb.in (10 Nm)

     3. Attach the wiring harness retainers.
     4. Install the wiring harness ground terminal and the stud bolt.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

178. Install the oil level indicator.

     Courtesy of FORD MOTOR COMPANY

179. Install a new oil cooler gasket.

     Courtesy of FORD MOTOR COMPANY

180. Install the oil cooler and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

181. 1. Install the idler pulley and bracket assembly and the bolts.

        Torque: 18 lb.ft (25 Nm)

     2. Install the accessory drive belt tensioner and the bolts.

        Torque: 18 lb.ft (25 Nm)

     3. Install the idler pulley and the bolt.

        Torque: 18 lb.ft (24 Nm)

     4. Install the idler pulley and the bolt.

        Torque: 35 lb.ft (48 Nm)

     5. Install the coolant pump pulley and the bolts.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

182. 1. Install the coolant pump and bolts.

        Torque: 62 lb.in (7 Nm)

     2. Connect the coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer

     Courtesy of FORD MOTOR COMPANY

183. Install the EGR coolant hose.

     Courtesy of FORD MOTOR COMPANY

184. Install the gaskets.

     Courtesy of FORD MOTOR COMPANY

185. • Attach the wiring harness retainers to the rear of the intake manifold.

     Courtesy of FORD MOTOR COMPANY

     1. Install the intake manifold and tighten the bolts in 2 stages.

        Torque: Stage 1: Bolts 1 through 8 in sequence: 44 lb.in (5 Nm) | Stage 2: Bolts 8 through 1 in reverse sequence: 89 lb.in (10 Nm)

186. 1. Install the EVAP canister purge valve.
     2. Follow directions to connect the quick release coupling type 19. Connect the EVAP canister purge valve vapor tube. Refer to: Quick Release Coupling .
     3. Connect the EVAP canister purge valve electrical connector.

     Courtesy of FORD MOTOR COMPANY

187. Install a new EGR tube gasket.

     Courtesy of FORD MOTOR COMPANY

188. Install a new EGR valve gasket.

     Courtesy of FORD MOTOR COMPANY

189. Install the EGR valve assembly and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

190. 1. Install the EGR tube nuts.

        Torque: 89 lb.in (10 Nm)

     2. Connect the engine wiring harness electrical connectors.
     3. Attach the engine wiring harness retainer.

     Courtesy of FORD MOTOR COMPANY

191. Install the EGR tube bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

192. 1. Install the ignition coil-on-plug and the stud bolt.

        Torque: 53 lb.in (6 Nm)

     2. Attach the wiring harness retainer.
     3. Connect the ignition coil-on-plug electrical connector.

     Courtesy of FORD MOTOR COMPANY

193. 1. Install differential pressure feedback EGR sensor and the clamps.
     2. Install the nut.

        Torque: 53 lb.in (6 Nm)

     Courtesy of FORD MOTOR COMPANY

194. Attach the wiring harness connector retainers.

     Courtesy of FORD MOTOR COMPANY

195. 1. Connect the throttle body electrical connector.
     2. Connect the differential pressure feedback EGR sensor electrical connector.
     3. Connect the MAP sensor electrical connector.
     4. Connect the cabin heater coolant pump electrical connector.
     5. Attach the wiring harness retainers.

     Courtesy of FORD MOTOR COMPANY

196. Follow directions to connect the quick release coupling type 3. Install the crankcase vent tube. Refer to: Quick Release Coupling .

     Courtesy of FORD MOTOR COMPANY

197. Clean the engine mount bracket-to-cylinder block surfaces of any dirt or foreign material prior to installation.

     Courtesy of FORD MOTOR COMPANY

198. Install the RH engine mount bracket and the new bolts.

     Torque: 52 lb.ft (70 Nm)

     Courtesy of FORD MOTOR COMPANY

199. Install commercially available quick links to the spreader bar and lift eyes. Install Special Service Tool: 303-1634 Lift Eyes (2), 303-1246 Engine Spreader Bar.

     Courtesy of FORD MOTOR COMPANY

200. Using a floor crane, remove the engine from the mounting stand. Use the General Equipment: Floor Crane. Use the General Equipment: Mounting Stand

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

202. NOTE: The crankshaft rear seal and retainer plate must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.
     1. Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the crankshaft rear seal and retainer plate.

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

     2. Overlap the beginning and ending of the sealant bead 15 mm (0.59 in).

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

     3. Apply 9 mm (0.35 in) beads of Motorcraft® High Performance Engine RTV Silicone that are 10 mm (0.40 in) in length as indicated in the graphic.

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

     Courtesy of FORD MOTOR COMPANY

203. Lubricate the outside surface of the tool with clean engine oil. Use Special Service Tool: 303-1250 Seal Installer, Rear Main.

     Courtesy of FORD MOTOR COMPANY

204. NOTE: The special tool must be inserted into the rear of the crankshaft seal to prevent the seal lip from rolling backwards.
     1. Insert the magnetic base of the special tool into the rear opening of the crankshaft seal. Install Special Service Tool: 303-1250 Seal Installer, Rear Main.
     2. The magnetic base of the special tool should protrude slightly from the front of the seal plate

     Courtesy of FORD MOTOR COMPANY

205. • Position the special tool and seal plate onto the end of the crankshaft. Use Special Service Tool: 303-1250 Seal Installer, Rear Main.
     • Slide the new crankshaft rear seal and retainer plate onto the crankshaft and into the installed position.

     Courtesy of FORD MOTOR COMPANY

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

207. 1. Install the CKP sensor and the bolt.

        Torque: 89 lb.in (10 Nm)

     2. Connect the CKP sensor electrical connector.
     3. Position the CKP sensor electrical connector insulator.

     Courtesy of FORD MOTOR COMPANY

208. Install the crankshaft sensor ring and the engine-to-transmission spacer plate.

     Courtesy of FORD MOTOR COMPANY

209. 1. Position the flexplate on the crankshaft.
     2. Hand start the bolts then rundown the bolts one turn at a time in sequence shown until the flexplate is snug against the rear face of the crankshaft.
     3. Final tighten the bolts in sequence shown.

        Torque: 59 lb.ft (80 Nm)

     Courtesy of FORD MOTOR COMPANY

210. Inspect the engine block dowels. If the dowels are damaged or missing, install new engine block dowels.

Courtesy of FORD MOTOR COMPANY