Section 16 (Engine - 5.2L 32V Ti-VCT - Supercharged): Assembly: Engine

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

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-142 (T80T-4000-J)Installer, Differential Bearing Cone
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W)Handle
Courtesy of FORD MOTOR COMPANY	303-103 (T74P-6375-A)Holding Tool, FlywheelT74P-77000-ATKIT-2009TC-F
Courtesy of FORD MOTOR COMPANY	303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1250Seal Installer, Rear MainTKIT-2006UFFLM
Courtesy of FORD MOTOR COMPANY	303-1508Installer, Front Crank Seal
Courtesy of FORD MOTOR COMPANY	303-1531Installer, Front Crank Seal and Damper
Courtesy of FORD MOTOR COMPANY	303-335 (T88T-6701-A)Installer, Front Cover Oil SealTKIT-1988-FLMTKIT-1988-F
Courtesy of FORD MOTOR COMPANY	303-448 (T93P-6303-A)Holding Tool, CrankshaftTKIT-1993-FLMTKIT-1993-LM
Courtesy of FORD MOTOR COMPANY	303-F047Lifting Bracket, Engine
Strap Wrench
Floor Crane
Mounting Stand
Piston Ring Compressor

Materials 

1. Record the main bearing code found on the front of the engine block.

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2. Record the main bearing code found on the rear of the crankshaft.

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3. NOTE: This chart is for selecting main bearings 1 and 5 only, the remaining bearings will be selected using a different chart in the next step.

   Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 5.

   • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing.
   • Repeat the above steps using the fifth letter of the block and crankshaft codes to select the No. 5 bearing.

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4. NOTE: This chart is for selecting main bearings 2, 3 and 4 only.

   Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2, 3 and 4.

   • Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 2 crankshaft main bearing
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing
   • Repeat the above steps using the third and fourth letters of the block and crankshaft codes to select the No. 3 and No. 4 bearings.

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5. Install the piston oil coolers and the bolts.

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

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

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7. 1. Lubricate the crankshaft bearing journals with clean engine oil.
   2. Install the crankshaft into the cylinder block.

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8. 1. Lubricate the thrust washer with clean engine oil.
   2. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.

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9. 1. Lubricate the fastener threads with clean engine oil.
   2. Install the main bearing caps and fasteners on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the cap fasteners.

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

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11. Tighten the vertical main bearing cap fasteners.

    Torque: Stage 1: 1 through 20: 177 lb.in (20 Nm) | Stage 2: 1 through 10: 30 lb.ft (40 Nm) | Stage 3: 11 through 20 : 48 lb.ft (65 Nm) | Stage 4: 1 through 20: 90°

    Fig 1: Main Bearing Tightening Sequence (1 Of 2)

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12. Install the cross-mounted main bearing cap fasteners.

    Torque: Stage 1: 22 lb.ft (30 Nm) | Stage 2: 60°

    Fig 2: Main Bearing Tightening Sequence (2 Of 2)

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13. • Check the crankshaft end play. Refer to: Specifications .
    • Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
    • Check the piston-to-cylinder block and piston ring clearances. Refer to: Specifications .
    • Assemble the pistons and position the piston ring gaps. Refer to: Piston .

14. • Lubricate the connecting rod bearings with clean engine oil.
    • Install the connecting rod bearings.

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15. 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.
    • Lubricate the piston with clean engine oil.
    • Using a piston ring compressor, install the piston. Use the General Equipment: Piston Ring Compressor

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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.

    Install the connecting rod cap and bearing.

    • Install the new bolts hand tight.

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17. Repeat the previous 2 steps for each of the remaining pistons.
18. Tighten the connecting rod bolts.

    Torque: Stage 1: 18 lb.ft (25 Nm) | Stage 2: 24 lb.ft (33 Nm) | Stage 3: 90°

    Fig 3: Connecting Rod Tightening Sequence

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19. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
20. NOTE: Oil pump must be held against the cylinder block until all bolts are tightened.
    1. Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil pump over the crankshaft until seated against the block.
    2. Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners hand tight.

       Torque: Stage 1: A: 89 lb.in (10 Nm) | Stage 2: B: 18 lb.ft (25 Nm) | Stage 3: C: 89 lb.in (10 Nm) | Stage 4: D: 18 lb.ft (25 Nm) | Stage 5: A: 45° | Stage 6: B: 75° | Stage 7: C: 45° | Stage 8: D: 75°

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21. Install the crankshaft sprocket.

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22. NOTE: If the rear crankshaft seal retaining plate is not secured within 5 minutes, the sealant must be removed and the sealing area cleaned. Failure to follow this procedure may cause future oil leaks.

    Apply a 3.75 mm (0.147 in) bead of silicone gasket and sealant to the chamfer of the rear crankshaft seal retaining plate sealing surface.

    Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

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23. Install the crankshaft rear seal retainer plate and the bolts.

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

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24. Install a new gasket.

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25. Install the oil filter adapter and the bolts.
    • Tighten in sequence.

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

    Fig 4: Oil Filter Adapter Tightening Sequence

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26. Install the KSs and the bolts.

    Torque: 177 lb.in (20 Nm)

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27. Install the dowels on the LH bank of the cylinder block.

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28. Install a new LH cylinder head gasket.

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

    Install the cylinder head and the new bolts.

    Torque: Stage 1: 22 lb.ft (30 Nm) | Stage 2: 37 lb.ft (50 Nm) | Stage 3: Tighten an additional : 90° | Stage 4: Tighten an additional : 90°

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30. Install the dowels on theRH bank of the cylinder block.

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31. Install a new RH cylinder head gasket.

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

    Install the cylinder head and the new bolts.

    Torque: Stage 1: 22 lb.ft (30 Nm) | Stage 2: 37 lb.ft (50 Nm) | Stage 3: Tighten an additional : 90° | Stage 4: Tighten an additional : 90°

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33. Using the special tool, rotate the crankshaft clockwise until the keyway is at the 12:00 position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.

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    NOTE: The LH camshafts, VCT units and timing chains must be installed first. Only turn the crankshaft as instructed. Failure to do so may result in the camshafts installed out of phase and serious damage to the engine will result.
34. NOTE: If the components are to be reinstalled, they must be installed in their original locations.
    1. Assemble the hydraulic lash adjusters onto the spring clips on the camshaft roller followers.
    2. Lubricate the camshaft roller followers and hydraulic lash adjusters with clean engine oil.
    3. Install the camshaft roller followers and hydraulic lash adjusters.

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35. • Lubricate the camshaft journals and lobes with clean engine oil.
    • Install the intake and exhaust camshafts and align the D-slots as shown in the illustration.

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36. NOTE: Do not tighten at this time.

    Install the camshaft bearing caps and the bolts.

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37. NOTE: Do not tighten at this time.

    Install the front camshaft bearing mega cap and the bolts.

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38. Tighten the bolts.

    Torque: Stage 1: 53 lb.in (6 Nm) | Stage 2: 53 lb. in (6 Nm) plus an additional : 45°

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39. Install new VCT system oil filters into the camshafts.

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40. Position the secondary timing chain onto the VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
    1. Dowel positions.
    2. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
    3. The timing mark on the exhaust VCT assembly should align with the single colored link.

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41. 1. Install the VCT unit and the secondary timing chain onto the camshafts. The timing mark on the exhaust VCT assembly should be located as shown.
    2. Using a wrench on the flats of the camshaft, have an assistant rotate the intake camshaft clockwise until the locating pin of the VCT engages into the end of the camshaft.
    3. Slide the VCT assemblies onto the camshafts until they are fully seated.

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42. Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward.

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43. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

    Install new intake and the exhaust VCT assembly bolts.

    Torque: Stage 1: 133 lb.in (15 Nm) | Stage 2: 90°

    Courtesy of FORD MOTOR COMPANY

44. Install the LH timing chain.
    • Align the colored link on the timing chain with the timing mark on the LHVCT assembly.
    • Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.

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45. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain guide. Return the crankshaft keyway to the 12:00 position after installing the LH timing chain guide.

    Install the LH timing chain guide and bolt.

    Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

46. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain arm. Return the crankshaft keyway to the 12:00 position after installing the LH timing chain arm.

    Install the LH timing chain tensioner arm.

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47. Compress the primary timing chain tensioner plunger, using an edge of a vise.

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48. 1. Using a small screwdriver, release and hold the ratchet lock mechanism.
    2. Push the ratchet arm into the tensioner.

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49. Install a pin into the hole of the tensioner housing to hold the plunger in place during installation.

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50. 1. Install the LH primary timing chain tensioner and bolts.

       Torque: 89 lb.in (10 Nm)

    2. Remove the holding pin from the tensioner.

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51. Using the special tool, rotate the crankshaft counterclockwise until the keyway is at the 11:00 position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.

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52. NOTE: If the components are to be reinstalled, they must be installed in their original locations.
    1. Assemble the hydraulic lash adjusters onto the spring clips on the camshaft roller followers.
    2. Lubricate the camshaft roller followers and hydraulic lash adjusters with clean engine oil.
    3. Install the camshaft roller followers and hydraulic lash adjusters.

    Courtesy of FORD MOTOR COMPANY

53. • Lubricate the camshaft journals and lobes with clean engine oil.
    • Install the intake and exhaust camshafts and align the D-slots as shown in the illustration.

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54. NOTE: Do not tighten at this time.

    Install the camshaft bearing caps and the bolts.

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55. NOTE: Do not tighten at this time.

    Install the front camshaft bearing mega cap and the bolts.

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56. Tighten the bolts.

    Torque: Stage 1: 53 lb.in (6 Nm) | Stage 2: 53 lb. in (6 Nm) plus an additional : 45°

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57. Install the new VCT system oil filters into the camshafts.

    Courtesy of FORD MOTOR COMPANY

58. Position the secondary timing chain onto the VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
    1. Dowel positions.
    2. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
    3. The timing mark on the exhaust VCT assembly should align with the single colored link.

    Courtesy of FORD MOTOR COMPANY

59. 1. Install the VCT unit and the secondary timing chain onto the camshafts. The timing mark on the exhaust VCT assembly should be located as shown.
    2. Using a wrench on the flats of the camshaft, have an assistant rotate the intake camshaft clockwise until the locating pin of the VCT engages into the end of the camshaft.
    3. Slide the VCT assemblies onto the camshafts until they are fully seated.

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60. Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward.

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61. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

    Install new intake and the exhaust VCT assembly bolts.

    Torque: Stage 1: 133 lb.in (15 Nm) | Stage 2: 90°

    Courtesy of FORD MOTOR COMPANY

62. Install the RH timing chain.
    • Align the colored link on the timing chain with the timing mark on the RHVCT assembly.
    • Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.

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63. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain guide. Return the crankshaft keyway to the 11:00 position after installing the RH timing chain guide.

    Install the RH timing chain guide and bolt.

    Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

64. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain arm. Return the crankshaft keyway to the 11:00 position after installing the RH timing chain arm.

    Install the RH timing chain tensioner arm.

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65. Compress the primary timing chain tensioner plunger, using an edge of a vise.

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66. 1. Using a small screwdriver, release and hold the ratchet lock mechanism.
    2. Push the ratchet arm into the tensioner.

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67. Install a pin into the hole of the tensioner housing to hold the plunger in place during installation.

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68. 1. Install the RH primary timing chain tensioner and bolts.

       Torque: 89 lb.in (10 Nm)

    2. Remove the holding pin from the tensioner.

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69. Install new gaskets on the engine front cover.

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70. NOTE: The VCT variable force solenoid pins must be fully depressed to avoid interference with the VCT valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.
    NOTE: RH shown, LH similar.

    Fully depress the VCT variable force solenoid pins.

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71. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

    Apply 15 mm (0.59 in) diameter drops of silicone gasket and sealant to the cylinder head-to-cylinder block joints.

    Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    Courtesy of FORD MOTOR COMPANY

72. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

    Install the engine front cover and the fasteners.

    Torque: Stage 1: Fasteners 1-15 : 18 lb.ft (25 Nm) | Stage 2: Fasteners 16-19 : 89 lb.in (10 Nm) | Stage 3: Fasteners 1-15 : 60° | Stage 4: Fasteners 16-19 : 45°

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73. Install the spacer.

    Torque: 18 lb.ft (25 Nm)

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74. NOTE: The oil pan must be installed and the fasteners finger tightened within 5 minutes of applying the sealant, and the fasteners must be final tightened within 15 minutes of applying the sealer. If this timing cannot be met the sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

    Apply 12 mm (0.47 in) drops of silicone gasket and sealant of silicone gasket and sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.

    Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    Courtesy of FORD MOTOR COMPANY

75. Install a new oil pan gasket.

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76. Install the oil pickup and fasteners.

    Torque: Oil pickup tube-to-oil pump bolts : Stage 1: 89 lb.in (10 Nm) | Stage 2: 45° Oil pickup tube-to-spacer bolt : 177 lb.in (20 Nm)

    Courtesy of FORD MOTOR COMPANY

77. Install the oil pan and the fasteners.

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

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78. Install the CMP sensors, the CKP sensor and the fasteners.

    Torque: 89 lb.in (10 Nm)

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79. Install the plug.

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80. Install a new coolant pump O-ring seal and lubricate with clean engine coolant.

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81. Install the coolant pump and bolts.

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

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82. 1. Install the coolant pump pulley and the bolts.

       Torque: 18 lb.ft (25 Nm)

    2. Install the idler pulley and the bolt.

       Torque: 35 lb.ft (48 Nm)

    3. Install the idler pulley and the bolt.

       Torque: 35 lb.ft (48 Nm)

    4. Install the belt tensioner and the bolt.

       Torque: 35 lb.ft (48 Nm)

    5. Install the belt tensioner and the bolt.

       Torque: 35 lb.ft (48 Nm)

    6. Install the idler pulley and the bolt.

       Torque: 35 lb.ft (48 Nm)

    7. Install the generator and the fasteners.

       Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

83. Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.

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84. 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., 303-1508 Installer, Front Crank Seal., 303-1531 Installer, Front Crank Seal and Damper.

    Courtesy of FORD MOTOR COMPANY

85. NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

    Apply silicone sealant to the Woodruff key slot in the crankshaft pulley.

    Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    Courtesy of FORD MOTOR COMPANY

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

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87. Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1508 Installer, Front Crank Seal.

    Courtesy of FORD MOTOR COMPANY

88. Install the bolts.

    Torque: 24 lb.ft (32 Nm)

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89. With the aid of an assistant, use a Strap Wrench to install a new crankshaft pulley bolt and the original washer. Use the General Equipment: Strap Wrench

    Torque: Stage 1: 66 lb.ft (90 Nm) | Stage 2: Loosen: 360° | Stage 3: 129 lb.ft (175 Nm) | Stage 4: Tighten an additional : 90°

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90. Install new studs.

    Torque: 18 lb.ft (25 Nm)

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91. Install a new gasket.

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92. 1. Position the LH exhaust manifold onto the engine and finger-tighten the nuts.
    2. Tighten the nuts in the sequence shown.

       Torque: Stage 1: 18 lb.ft (24 Nm) | Stage 2: 24 lb.ft (32 Nm)

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93. Install new studs.

    Torque: 18 lb.ft (25 Nm)

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94. Install a new gasket.

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95. 1. Position the RH exhaust manifold onto the engine and finger-tighten the nuts.
    2. Tighten the nuts in the sequence shown.

       Torque: Stage 1: 18 lb.ft (24 Nm) | Stage 2: 24 lb.ft (32 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Using the special tools, install new VCT variable force solenoid seals. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.

    Courtesy of FORD MOTOR COMPANY

98. Install a new gasket.

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99. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned.

    Apply 12 mm (0.47 in) drops of silicone gasket and sealant to the engine front cover-to-cylinder head joints.

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

    Courtesy of FORD MOTOR COMPANY

100. NOTE: Do not final tighten the bolts at this time.

     Install the valve cover and the bolts finger tight.

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101. 1. Push the oil level indicator lower tube into the engine.
     2. Rotate the oil level indicator lower tube clockwise.
     3. Verify the tab is locked in place.

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102. NOTE: Do not final tighten the bolt at this time.
     1. Install the upper oil level indicator tube and the bolt finger tight.
     2. Install the oil level indicator.

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103. Tighten the bolts.

     Torque: 89 lb.in (10 Nm)

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104. 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

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

     Using the special tools, install new VCT variable force solenoid seals. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.

     Courtesy of FORD MOTOR COMPANY

106. Install a new gasket.

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107. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned.

     Apply 12 mm (0.47 in) drops of silicone gasket and sealant to the engine front cover-to-cylinder head joints.

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

     Courtesy of FORD MOTOR COMPANY

108. Install the valve cover and tighten the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

109. Install the spark plugs.

     Torque: 133 lb.in (15 Nm)

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110. Install the ignition coils and the bolts.

     Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 45°

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111. • Position the wiring harness on the engine.
     • Install the ground wire and the nut.

       Torque: 89 lb.in (10 Nm)

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112. • Position the harness and attach the wiring harness retainers.
     • Connect the engine wiring harness electrical connectors.

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113. Install the RH spark plug cover.

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114. • Position the harness and attach the wiring harness retainers.
     • Connect the engine wiring harness electrical connectors.

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115. Install the LH spark plug cover.

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116. Connect the engine wiring harness electrical connectors.

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117. Attach the engine wiring harness retainer.

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118. • Connect the engine wiring harness electrical connector.
     1. Reposition the wiring harness electrical connector insulator.
     • Attach the engine wiring harness retainers.

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119. • Connect the engine wiring harness electrical connectors.
     • Reposition the wiring harness electrical connector insulator.
     • Attach the engine wiring harness retainers.
     • Install the ground cable and the nut.

       Torque: 89 lb.in (10 Nm)

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120. • Connect the engine wiring harness electrical connectors.
     • Reposition the wiring harness electrical connector insulators.
     • Attach the engine wiring harness retainers.

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121. Install the special tool and remove the engine from the engine stand using a floor crane. Install Special Service Tool: 303-F047 Lifting Bracket, Engine.Use the General Equipment: Floor CraneUse the General Equipment: Mounting Stand

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122. Lubricate the seal bore and the seal lips with clean engine oil.

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123. • Position the special tool onto the end of the crankshaft. Use Special Service Tool: 303-1250 Seal Installer, Rear Main.
     • Slide the new crankshaft rear seal onto the tool.

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124. Using the special tools, install the crankshaft rear seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1250 Seal Installer, Rear Main.

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

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126. Install the flywheel and the bolts. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

     Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 177 lb.in (20 Nm) | Stage 3: 59 lb.ft (80 Nm)

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