Engine Block Skirt Stiffener

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	303-1250 Seal Installer, Rear Main | TKIT-2006UFFLM
Courtesy of FORD MOTOR COMPANY	303-1531 Installer, Front Crank Seal and Damper
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2) | TKIT-2014D-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
Vise
Vise Jaw Protectors

Materials 

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

   Courtesy of FORD MOTOR COMPANY

2. 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)

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

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

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

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5. 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.

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

   Tighten the engine block skirt stiffener bolts.

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

   Fig 1: Engine Block Skirt Stiffener Tightening Sequence

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

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8. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
9. 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°

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

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11. Install the oil pump pickup and bolts.

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

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12. Install the timing chain sprocket.

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

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14. Install the RH timing chain guide and bolts.

    Torque: 89 lb.in (10 Nm)

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15. Install the RH timing chain tensioner arm.

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

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

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

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

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

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

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20. 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.

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

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

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23. Install new engine front cover gaskets.

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24. 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.

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25. 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

26. 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

27. 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°

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

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29. 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.

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30. 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,

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

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32. 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.

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33. 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°

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34. Install the outer pulley and bolts.

    Torque: 26 lb.ft (35 Nm)

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

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

    Courtesy of FORD MOTOR COMPANY

36. Install new gaskets.

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

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

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

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

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 89 lb.in (10 Nm)

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40. 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.

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41. Install a new gasket.

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

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43. 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

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

    Torque: 89 lb.in (10 Nm)

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45. Install the bracket and nut.

    Torque: 55 lb.in (6.2 Nm)

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

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

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48. 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

49. Install the oil pan and the bolts.

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

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

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51. Install a new turbocharger oil return tube O-ring seal, then lubricate with clean engine oil.

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52. 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)

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53. Install a new TC oil return tube-to-engine block gasket.

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54. Install a new turbocharger oil return tube O-ring seal, then lubricate with clean engine oil.

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55. 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

56. Install a new coolant pump gasket.

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57. 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.

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58. 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°

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59. 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)

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60. Install a new EGR tube gasket.

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61. Install a new EGR tube gasket.

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

    Torque: 89 lb.in (10 Nm)

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

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

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

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66. 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.

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67. 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

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

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

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

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71. 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

72. 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.

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73. 1. Connect the KS wiring harness 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

74. Install the oil level indicator.

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75. Install a new oil cooler gasket.

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76. Install the oil cooler and the bolts.

    Torque: 89 lb.in (10 Nm)

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77. 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)

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78. 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

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79. Install the EGR coolant hose.

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80. Install the gaskets.

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

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    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)

82. 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.

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83. Install a new EGR tube gasket.

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84. Install a new EGR valve gasket.

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85. Install the EGR valve assembly and the bolts.

    Torque: 89 lb.in (10 Nm)

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86. 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.

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87. Install the EGR tube bolts.

    Torque: 89 lb.in (10 Nm)

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88. 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.

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

       Torque: 53 lb.in (6 Nm)

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90. Attach the wiring harness connector retainers.

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91. 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.

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

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

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

    Torque: 52 lb.ft (70 Nm)

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95. 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.

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

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

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98. 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

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

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100. 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

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101. • 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.

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

     Torque: 89 lb.in (10 Nm)

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103. 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.

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

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105. 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)

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

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107. Install the engine into the vehicle. Refer to: Engine .