Section 379 (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.

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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.

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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.

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

   Torque: 89 lb.in (10 Nm)

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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.

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

   Install the crankshaft into the cylinder block.

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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.

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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.

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

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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

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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: Piston .

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

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    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.

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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.

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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.
    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.

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17. 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.

    Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine block skirt stiffener.

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

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

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19. 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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20. 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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21. 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)

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

    Install a new ECT sensor.

    Torque: 20 lb.ft (27 Nm)

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

       Torque: 97 lb.in (11 Nm)

    2. Connect the ECT sensor electrical connector.

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

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25. 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.

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26. 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.

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27. Install a new cylinder head gasket.

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28. • 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°

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29. Inspect the O-ring and replace if damaged.

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30. 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

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31. NOTE: Do

    not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.

    NOTE: If the original hydraulic lash adjusters 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.

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32. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
    NOTE: It is not necessary to position the scarf-cut seal ends when installing the camshafts.

    Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown below in the illustration.

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33. 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)

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34. NOTE: Do not tighten at this time.

    Install the camshaft bearing caps and the bolts.

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35. NOTE: Do not tighten at this time.

    Install the front camshaft bearing mega cap and the bolts.

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36. Tighten the bolts.

    Torque: 89 lb.in (10 Nm)

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37. 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 below 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.

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38. Install a new cylinder head gasket.

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39. • 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°

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40. Inspect the O-ring and replace if damaged.

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41. 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

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42. NOTE: Do

    not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.

    NOTE: If the original hydraulic lash adjusters 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.

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43. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
    NOTE: It is not necessary to position the scarf-cut seal ends when installing the camshafts.

    Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown below in the illustration.

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44. 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)

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45. NOTE: Do not tighten at this time.

    Install the camshaft bearing caps and the bolts.

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46. NOTE: Do not tighten at this time.

    Install the front camshaft bearing mega cap and the bolts.

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47. Tighten the bolts.

    Torque: 89 lb.in (10 Nm)

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48. 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 below 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.

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49. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
50. 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.

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51. Install the timing chain sprocket.

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52. 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.

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53. Install the LH timing chain guide and bolts.

    Torque: 89 lb.in (10 Nm)

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54. Install the LH timing chain tensioner arm.

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

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56. 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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57. 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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58. 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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59. 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.

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60. Install the crankshaft sprocket.

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

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62. 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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63. Install the original crankshaft pulley bolt.

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64. 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.

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65. Remove and discard the original crankshaft pulley bolt.

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66. Install the timing chain sprocket.

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67. 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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68. Install the RH timing chain guide and bolts.

    Torque: 89 lb.in (10 Nm)

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69. Install the RH timing chain tensioner arm.

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

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71. 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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72. 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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73. 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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74. 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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75. Install new engine front cover gaskets.

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76. NOTE: Lubricate the new oil gallery seal with clean engine oil.

    Lubricate and install a new oil gallery seal (6G068).

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77. 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)

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78. 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)

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79. Install the engine front cover and the fasteners.

    Torque: Stage 1: Tighten bolts 1 through 11 to: 18 lb.ft (24 Nm) | Stage 2: Tighten bolts 12 through 13 to: 35 lb.ft (48 Nm) | Stage 3: Tighten bolts 14 through 20 to: 18 lb.ft (24 Nm)

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80. Install a new oil pump seal.

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81. 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) bead 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)

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82. 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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83. Lubricate the engine front cover bore 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, 303-1531 Installer, Front Crank Seal and Damper.

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85. Lubricate the crankshaft front seal inner lip with clean engine oil.

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

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88. NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).

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

    Torque: Stage 1: 140 lb.ft (190 Nm) | Stage 2: Loosen: 360° | Stage 3: 26 lb.ft (35 Nm) | Stage 4: 270°

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

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90. 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.

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91. 1. Lubricate the camshaft roller follower with clean engine oil.
    2. Install the camshaft roller follower.
    3. Turn the knob on the special tool counterclockwise to raise the valve and spring. Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower.
    • Repeat steps for the remaining camshaft roller followers.

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92. 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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93. Install new gaskets.

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94. 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 engine front cover-to-cylinder head joints.

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

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

    Torque: 89 lb.in (10 Nm)

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96. Install the oil level indicator.

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97. 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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98. Install a new gasket.

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99. 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 engine front cover-to-cylinder head joints.

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

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

     Torque: 89 lb.in (10 Nm)

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101. Install new TC mounting studs.

     Torque: 102 lb.in (11.5 Nm)

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102. Install a new TC gasket.

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103. Install a new turbocharger end coolant supply tube O-ring seal. Lubricate the NEW O-ring seal with clean engine coolant.

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104. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
     NOTE: Install the TC coolant supply tube to the engine block while installing the TC.

     Install the TC and then loosely install the new TC bolt and nuts. Install the TC coolant supply tube to the engine block while installing the TC.

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

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105. Tighten the TC bolt.

     Torque: 44 lb.ft (60 Nm)

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106. 1. Tighten the TC nut.

        Torque: 44 lb.ft (60 Nm)

     2. Tighten the TC nut.

        Torque: 27 lb.ft (37 Nm)

     Courtesy of FORD MOTOR COMPANY

107. Re-tighten the TC bolt.

     Torque: 44 lb.ft (60 Nm)

     Courtesy of FORD MOTOR COMPANY

108. 1. Re-tighten the TC nut.

        Torque: 44 lb.ft (60 Nm)

     2. Re-tighten the TC nut.

        Torque: 27 lb.ft (37 Nm)

     Courtesy of FORD MOTOR COMPANY

109. Install and tighten the TC coolant supply tube bolt.

     Torque: 18 lb.ft (24 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

112. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

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

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

     Courtesy of FORD MOTOR COMPANY

114. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

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

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

116. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
     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.

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

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

117. Install and then tighten a new TC mounting stud.

     Torque: 102 lb.in (11.5 Nm)

     Courtesy of FORD MOTOR COMPANY

118. Install a new TC gasket.

     Courtesy of FORD MOTOR COMPANY

119. Install a new TC coolant supply tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

     Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

     Courtesy of FORD MOTOR COMPANY

120. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
     NOTE: Install the TC coolant supply tube to the engine block while installing the TC.

     Loosely install the new TC retainers. Install the TC coolant supply tube to the engine block while installing the TC.

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

     Courtesy of FORD MOTOR COMPANY

121. Install and tighten the TC coolant supply tube bolt.

     Torque: 18 lb.ft (24 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

124. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

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

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

126. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

     Install the TC oil supply tube, then loosely install the oil supply tube bolt.

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

     Courtesy of FORD MOTOR COMPANY

127. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

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

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

128. Tighten the TC oil supply tube bolt.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

129. Install and then tighten a new TC mounting stud.

     Torque: 102 lb.in (11.5 Nm)

     Courtesy of FORD MOTOR COMPANY

130. Loosely install the upper left TC nut.

     Courtesy of FORD MOTOR COMPANY

131. Tighten the turbocharger retainers in the following sequence.
     1. Tighten the bolt.

        Torque: 44 lb.ft (60 Nm)

     2. Tighten the nut.

        Torque: 44 lb.ft (60 Nm)

     3. Tighten the nut.

        Torque: 27 lb.ft (37 Nm)

     4. Re-tighten the bolt.

        Torque: 44 lb.ft (60 Nm)

     5. Re-tighten the nut.

        Torque: 44 lb.ft (60 Nm)

     6. Re-tighten the nut.

        Torque: 27 lb.ft (37 Nm)

     Fig 2: Turbocharger Retainers Tightening Sequence

     Courtesy of FORD MOTOR COMPANY
132. Install a new TC coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

     Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

     Courtesy of FORD MOTOR COMPANY

133. NOTE: 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. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

     Install and connect the turbocharger coolant return tube and clamp, then install and tighten the turbocharger coolant return tube bolt.

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

134. • Lubricate the inside and the outside diameter of the grommet with clean engine coolant.

       Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

     • Install the grommet so it is flush with the rear of the coolant pump housing.

     Courtesy of FORD MOTOR COMPANY

135. Install a new coolant pump gasket.

     Courtesy of FORD MOTOR COMPANY

136. 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 1-7: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

     • Torque

       : Fastener 8: 18 lb.ft (24 Nm)

     Fig 3: Coolant Pump Tightening Sequence

     Courtesy of FORD MOTOR COMPANY
137. NOTE: Lubricate with clean engine oil.

     Lubricate the new EGR cooler O-ring seals with clean engine oil.

     Courtesy of FORD MOTOR COMPANY

138. Install the EGR cooler and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

139. Install a new EGR tube gasket.

     Courtesy of FORD MOTOR COMPANY

140. Install a new EGR tube gasket.

     Courtesy of FORD MOTOR COMPANY

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

142. Inspect the gaskets and replace if damaged.

     Courtesy of FORD MOTOR COMPANY

143. NOTE: If the brake vacuum pump is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Failure to follow this procedure can cause future oil leakage.

     Apply 8 mm (0.14 in) beads of Motorcraft® High Performance Engine RTV Silicone as shown below.

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

     Courtesy of FORD MOTOR COMPANY

144. Install the brake vacuum pump and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

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

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

     Courtesy of FORD MOTOR COMPANY

147. 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

148. 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

149. NOTE: Align the notch on the high-pressure fuel pump tappet and with the groove in the high-pressure fuel pump drive unit bore.

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

     Courtesy of FORD MOTOR COMPANY

150. NOTE: Apply clean engine oil to the high-pressure fuel pump O-ring seals.

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

     Courtesy of FORD MOTOR COMPANY

151. 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: 177 lb.in (20 Nm) | Stage 2: 45°

     Courtesy of FORD MOTOR COMPANY

152. NOTE: Make sure that a new high-pressure fuel tubes are installed.

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

     Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 89 lb.in (10 Nm) | Stage 3: 25°

     Courtesy of FORD MOTOR COMPANY

153. 1. Install the fuel manifold and the stud bolts.

        Torque: 89 lb.in (10 Nm)

     2. Connect the quick release coupling. Refer to: QUICK RELEASE COUPLING . .
     3. Connect the fuel tube spring lock couplings. Refer to: Spring Lock Couplings .

     Courtesy of FORD MOTOR COMPANY

154. 1. Attach the wiring harness retainers.
     2. Install the spring lock coupling retaining clips.

     Courtesy of FORD MOTOR COMPANY

155. Install the hose and clamp.

     Courtesy of FORD MOTOR COMPANY

156. Install the high pressure fuel pump insulator.

     Courtesy of FORD MOTOR COMPANY

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

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

159. 1. Install the ignition coils.
     2. Install the stud bolts.

        Torque: 53 lb.in (6 Nm)

     Courtesy of FORD MOTOR COMPANY

160. 1. Install the vacuum harness onto the engine and connect the vacuum hose and clamp.
     2. Attach the vacuum hose retainer.
     3. Install the vacuum control solenoid bolts.

        Torque: 62 lb.in (7 Nm)

     4. Connect the vacuum tube quick release coupling. Refer to: QUICK RELEASE COUPLING . .

     Courtesy of FORD MOTOR COMPANY

161. 1. Install the solenoid bolt.

        Torque: 62 lb.in (7 Nm)

     2. Attach the vacuum hose retainer.
     3. Connect the vacuum hose and clamp.

     Courtesy of FORD MOTOR COMPANY

162. Install the engine wiring harness onto the engine.
     • Connect the engine wiring harness electrical connectors and attach the retainers.

     Courtesy of FORD MOTOR COMPANY

163. Connect the engine wiring harness electrical connectors and attach the retainers.

     Courtesy of FORD MOTOR COMPANY

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

     Courtesy of FORD MOTOR COMPANY

165. 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

166. 1. Connect the KS wiring harness connector.
     2. Attach the wiring harness retainers.
     3. Install the wiring harness ground terminal and the bolt.

        Torque: 89 lb.in (10 Nm)

     4. Install the wiring harness ground terminal and the stud bolt.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

167. Install a new oil cooler gasket.

     Courtesy of FORD MOTOR COMPANY

168. Install the oil cooler and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

169. 1. Position the bracket with heater hose and install the nuts.

        Torque: 89 lb.in (10 Nm)

     2. Connect the heater hose and clamp.

     Courtesy of FORD MOTOR COMPANY

170. Install the A/C compressor and the bolts.

     Torque: 18 lb.ft (25 Nm)

     Courtesy of FORD MOTOR COMPANY

171. 1. NOTE: Do not tighten coolant pump pulley bolts at this time.

        Install the coolant pump pulley and the bolts.

     2. Install the idler pulley and the bolt.

        Torque: 18 lb.ft (24 Nm)

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

        Torque: 18 lb.ft (25 Nm)

     4. Install the idler pulley and the bolt.

        Torque: 35 lb.ft (48 Nm)

     5. Install the generator, the bolt and the nut.

        Torque: 35 lb.ft (48 Nm)

     Courtesy of FORD MOTOR COMPANY

172. 1. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
     2. Tighten the coolant pump pulley bolts.

        Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

173. Make sure the accessory drive belt is correctly seated on all pulleys.

     Courtesy of FORD MOTOR COMPANY

174. Install the auxiliary coolant pump and hose assembly and the bolts.

     Torque: 62 lb.in (7 Nm)

     Courtesy of FORD MOTOR COMPANY

175. • Connect the coolant hoses.
     • Connect the auxiliary coolant pump electrical connector.

     Courtesy of FORD MOTOR COMPANY

176. Install the engine mount and the new bolts.

     Torque: 57 lb.ft (77 Nm)

     Courtesy of FORD MOTOR COMPANY

177. Install the engine mount-to-cylinder block bracket and the new bolts.

     Torque: 57 lb.ft (77 Nm)

     Courtesy of FORD MOTOR COMPANY

178. Using a floor crane, remove the engine from the mounting stand. Install Special Service Tool: 303-1634 Lift Eyes (2), 303-1246 Engine Spreader Bar. Use the General Equipment: Floor Crane. Use the General Equipment: Mounting Stand

     Courtesy of FORD MOTOR COMPANY

179. Lubricate the crankshaft rear seal lips with clean engine oil.

     Courtesy of FORD MOTOR COMPANY

180. 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

181. • 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 and retainer plate onto the tool and into the installed position.

     Courtesy of FORD MOTOR COMPANY

182. 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

183. 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

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

     Courtesy of FORD MOTOR COMPANY

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

        Torque: 59 lb.ft (80 Nm)

Fig 4: Flexplate Bolts Tightening Sequence

Courtesy of FORD MOTOR COMPANY