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
Flat-Bladed Screwdriver
Vise
Vise Jaw Protectors

Materials 

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

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3. 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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4. 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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5. 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

   Courtesy of FORD MOTOR COMPANY
6. Install the oil pump drive belt onto the crankshaft sprocket.

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7. 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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8. Install the timing chain sprocket.

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9. 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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10. Install the RH timing chain guide and bolts.

    Torque: 89 lb.in (10 Nm)

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11. Install the RH timing chain tensioner arm.

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

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13. 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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14. 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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15. 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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16. 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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17. Install new engine front cover gaskets.

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

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

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19. 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

20. 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

21. 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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22. Install a new oil pump seal.

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23. 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)

    Courtesy of FORD MOTOR COMPANY

24. Install the oil pan and the bolts.

    Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

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

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

    Courtesy of FORD MOTOR COMPANY

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

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

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

    Courtesy of FORD MOTOR COMPANY

30. 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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31. 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

32. Install new gaskets.

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33. 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)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 89 lb.in (10 Nm)

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35. Install the oil level indicator.

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36. 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

37. Install a new gasket.

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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 engine front cover-to-cylinder head joints.

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

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

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42. 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

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

45. 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

46. • 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.

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47. Install a new coolant pump gasket.

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48. 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)

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49. NOTE: Lubricate with clean engine oil.

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

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50. Install the EGR cooler and the bolts.

    Torque: 89 lb.in (10 Nm)

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51. Install a new EGR tube gasket.

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52. Install a new EGR tube gasket.

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

    Torque: 89 lb.in (10 Nm)

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

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

       Torque: 53 lb.in (6 Nm)

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56. 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 . .

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57. 1. Install the solenoid bolt.

       Torque: 62 lb.in (7 Nm)

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

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

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

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

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61. 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)

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62. 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)

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63. Install a new oil cooler gasket.

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64. Install the oil cooler and the bolts.

    Torque: 89 lb.in (10 Nm)

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

       Torque: 89 lb.in (10 Nm)

    2. Connect the heater hose and clamp.

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

    Torque: 18 lb.ft (25 Nm)

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67. 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)

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68. 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

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

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

    Torque: 62 lb.in (7 Nm)

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

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72. Install the engine mount and the new bolts.

    Torque: 57 lb.ft (77 Nm)

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

    Torque: 57 lb.ft (77 Nm)

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74. 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

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

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76. 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

77. • 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.

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78. 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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79. 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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80. Install the crankshaft sensor ring and the engine-to-transmission spacer plate.

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81. 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 2: Flexplate Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
82. Install the engine into the vehicle. Refer to: Engine - Body Off .