Section 673 (Engine - 5.0L 32V Ti-VCT): Assembly: Engine
For information on Ford Color Coded Illustrations refer to OEM COLOR CODING INFORMATION
Special Tool(s) / General Equipment
| 205-142 (T80T-4000-J)Installer, Differential Bearing Cone | |
|---|---|
| 205-153 (T80T-4000-W)Handle | |
| 303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 303-1250Seal Installer, Rear MainTKIT-2006UFFLM | |
| 303-1531Installer, Front Crank Seal and Damper | |
| 303-335 (T88T-6701-A)Installer, Front Cover Oil SealTKIT-1988-FLMTKIT-1988-F | |
| 303-448 (T93P-6303-A)Holding Tool, CrankshaftTKIT-1993-FLMTKIT-1993-LM | |
| 303-F047Lifting Bracket, Engine | |
| Strap Wrench | |
| Floor Crane | |
| Mounting Stand | |
| Piston Ring Compressor | |
| Vise |
Materials
| Name | Specification |
|---|---|
| Motorcraft® High Performance Engine RTV SiliconeTA-357 | WSE-M4G323-A6 |
- Record the main bearing code found on the front of the engine block.
- Record the main bearing code found on the rear of the crankshaft.
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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.
- Maximum crankshaft journal diameter
- Minimum block bore diameter
- 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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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.
- Maximum crankshaft journal diameter
- Minimum block bore diameter
- 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.
- Install the piston cooling jets and bolts.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 deg.
- 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.
-
- Lubricate the crankshaft bearing journals with clean engine oil.
- Install the crankshaft into the cylinder block.
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NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft thrust surface).
- Lubricate the thrust washer with clean engine oil.
- Push the crankshaft rearward.
- Install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
-
- Lubricate the fastener threads with clean engine oil.
- 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.
- Push the crankshaft forward to seat the crankshaft thrust washer.
- 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 deg.
- Install the cross-mounted main bearing cap fasteners.
Torque:Stage 1: 22 lb.ft (30 Nm)
Stage 2: 60 deg.
-
- Check the crankshaft end play. Refer to: 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 .
- Lubricate with clean engine oil and install the connecting rod bearings.
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NOTE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.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.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.NOTE: 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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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.
- Repeat the previous 3 steps for each of the remaining pistons.
- Tighten the connecting rod bolts.
Torque:Stage 1: 177 lb.in (20 Nm)
Stage 2: 28 lb.ft (38 Nm)
Stage 3: 105 deg.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
-
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® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install the crankshaft rear seal retainer plate and the bolts.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 30 deg.
- Install the cam drive install aid and the fasteners.
Torque: 1:Stage 1: 177 lb.in (20 Nm)
Stage 2: 60 deg. 2:
Stage 3: 18 lb.ft (25 Nm)
Stage 4: 75 deg.
- Position the oil pump drive belt on the crankshaft sprocket.
- Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
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NOTE: Make sure the oil pump drive belt teeth are engaged in the crankshaft sprocket prior to installing the oil pump.
- Install the oil pump sprocket into the oil pump drive belt.
- Raise the rear of the oil pump assembly into the installed position.
- Install the oil pump bolts.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 deg.
-
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths.
Make sure that the mating faces are clean and free of foreign material.
- Install a new oil pan gasket.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
-
NOTE: If the oil pan is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage. If this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque all of the fasteners within 1 hour of applying the sealer.
Apply 15 mm (0.59 in) diameter drops of silicone gasket and sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces.
Material
: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
-
NOTE: Fastener locations 1 and 3 are stud bolts.
Using a new gasket, install the oil pan and the bolts.
Torque:Stage 1: 18 lb.in (2 Nm)
Stage 2: 89 lb.in (10 Nm)
Stage 3: 45 deg.
- Install a new oil filter adapter gasket.
- Install the oil filter adapter and the bolts.
Torque:Stage 1: 133 lb.in (15 Nm)
Stage 2: 177 lb.in (20 Nm)
Stage 3: 60 deg.
-
NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
Install a new oil cooler and the threaded fitting.
Torque: 43 lb.ft (58 Nm)
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NOTE: The CKP sensor must be positioned into the crankshaft rear seal retainer plate and be flush against the boss on the engine block before the bolt is installed. If the CKP sensor is installed incorrectly, the CKP sensor can be damaged.
- Install the CKP sensor must be positioned into the crankshaft rear seal retainer plate.
- Make sure the CKP sensor is flush with the engine block boss.
- Install the bolt.
Torque: 89 lb.in (10 Nm)
- Install the crankshaft sprocket.
- Using the special tool, rotate the crankshaft clockwise until the keyway is at the 4:00 position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.
- Install the dowels on the LH bank of the cylinder block.
- Install a new LH cylinder head gasket.
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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: Bolts 1-10 in sequence: 18 lb.ft (25 Nm)
Stage 2: Bolts 1-10 in sequence: 55 lb.ft (75 Nm)
Stage 3: Bolt 1: Loosen: 180 deg.
Stage 4: Bolt 1: 37 lb.ft (50 Nm)
Stage 5: Bolt 1: 240 deg.
- Perform stages 3, 4 and 5 on bolts 2 through 10 (complete all three stages to each bolt before moving on to the next bolt in sequence).
- Install the cylinder head and the new bolts.
- Lubricate the hydraulic lash adjusters and roller followers with clean engine oil.
-
NOTE: If the components are to be reinstalled, they must be installed in their original locations.
- Assemble the hydraulic lash adjusters onto the spring clips on the camshaft roller followers.
- Install the camshaft roller follower and hydraulic lash adjuster assemblies.
- Install a new gasket.
- Make sure the timing mark is in the position shown.
- Lubricate the camshafts with clean engine oil.
- Lubricate the rocker arms with clean engine oil.
- Install the camshaft and carrier assembly.
Torque:Stage 1: 106 lb.in (12 Nm)
Stage 2: 106 lb.in (12 Nm)
Stage 3: 60 deg.
- Inspect the O-ring seal. If damaged, discard the oil tube assembly.
- Apply clean engine oil to the O-ring seal and oil tube.
- Install the oil tube and tighten the fasteners in sequence.
Torque: 89 lb.in (10 Nm)
- Inspect the seals. If damaged, discard the oil tube assembly.
- Apply clean engine oil to the seals and oil tube.
- Install the oil tube and tighten the fasteners in sequence.
Torque: 89 lb.in (10 Nm)
- 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.
-
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 4:00 position after installing the LH timing chain guide.
Install the LH timing chain guide and bolt.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 25 deg.
-
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 4:00 position after installing the LH timing chain arm.
Install the LH timing chain tensioner arm.
-
- Compress the primary timing chain tensioner plunger, using an edge of a vise. Use the General Equipment: Vise
- Install a suitable pin into the hole of the tensioner housing to hold the plunger in place during installation.
-
- Install the LH primary timing chain tensioner and bolts.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 25 deg.
- Remove the holding pin from the tensioner.
- Install the LH primary timing chain tensioner and bolts.
- Using the special tool, rotate the crankshaft clockwise until the keyway is at the 9:00 position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.
- Install the dowels on the RH bank of the cylinder block.
- Install the new cylinder head gasket.
-
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: Bolts 1-10 in sequence: 18 lb.ft (25 Nm)
Stage 2: Bolts 1-10 in sequence: 55 lb.ft (75 Nm)
Stage 3: Bolt 1: Loosen: 180 deg.
Stage 4: Bolt 1: 37 lb.ft (50 Nm)
Stage 5: Bolt 1: 240 deg.
- Perform stages 3, 4 and 5 on bolts 2 through 10 (complete all three stages to each bolt before moving on to the next bolt in sequence).
- Install the cylinder head and the new bolts.
- Lubricate the hydraulic lash adjusters and roller followers with clean engine oil.
-
NOTE: If the components are to be reinstalled, they must be installed in their original locations.
- Assemble the hydraulic lash adjusters onto the spring clips on the camshaft roller followers.
- Install the camshaft roller follower and hydraulic lash adjuster assemblies.
- Install a new gasket.
- Make sure the timing mark is in the position shown.
- Lubricate the camshafts with clean engine oil.
- Lubricate the rocker arms with clean engine oil.
- Install the camshaft and carrier assembly.
Torque:Stage 1: 106 lb.in (12 Nm)
Stage 2: 106 lb.in (12 Nm)
Stage 3: 60 deg.
- Install the camshaft cap and bolts.
Torque:Stage 1: 53 lb.in (6 Nm)
Stage 2: 90 deg.
- Inspect the O-ring seal. If damaged, discard the oil tube assembly.
- Apply clean engine oil to the O-ring seal and oil tube.
- Install the oil tube and tighten the fasteners in sequence.
Torque: 89 lb.in (10 Nm)
- Inspect the seals. If damaged, discard the oil tube assembly.
- Apply clean engine oil to the seals and oil tube.
- Install the oil tube and tighten the fasteners in sequence.
Torque: 89 lb.in (10 Nm)
- 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.
-
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 9:00 position after installing the RH timing chain guide.
Install the RH timing chain guide and bolt.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 25 deg.
-
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 9:00 position after installing the RH timing chain arm.
Install the RH timing chain tensioner arm.
-
- Compress the primary timing chain tensioner plunger, using an edge of a vise. Use the General Equipment: Vise
- Install a suitable pin into the hole of the tensioner housing to hold the plunger in place during installation.
-
- Install the RH primary timing chain tensioner and bolts.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 25 deg.
- Remove the holding pin from the tensioner.
- Install the RH primary timing chain tensioner and bolts.
- Install the 8 spark plugs.
Torque: 128 lb.in (14.5 Nm)
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Install new gaskets on the engine front cover.
-
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: LH shown, RH similar.
Fully depress the VCT variable force solenoid pins.
-
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 a 15 mm (0.59 in) diameter drop of silicone gasket and sealant to the camshaft carrier-to-cylinder head joints, the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints.
Material
: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
-
NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.
Position the engine front cover onto the dowels.
-
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 bolts and stud bolts.
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 deg.
Stage 4: Fasteners 16-19 : 45 deg.
- Using a 10 mm Hex Bit, turn the engine front cover-to-oil filter adapter jack screw into contact with the oil filter adapter.
Torque: 44 lb.in (5 Nm)
- Install the engine front cover-to-oil filter adapter bolt.
Torque:Stage 1: 18 lb.ft (25 Nm)
Stage 2: 60 deg.
-
NOTE: Installation of a new seal is only required if damaged seal was removed.
Using the special tools, install a new spark plug tube seal(s). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
-
NOTE: Installation of a new seal is only required if damaged seal was removed.
Using the special tools, install a new seal(s). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
- Install a new gasket.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
-
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 an 12 mm (0.47 in) drop 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)
- Install the valve cover and tighten the bolts.
Torque: 89 lb.in (10 Nm)
-
NOTE: Installation of a new seal is only required if damaged seal was removed.
Using the special tools, install a new spark plug tube seal(s). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
-
NOTE: Installation of a new seal is only required if damaged seal was removed.
Using the special tools, install a new seal(s). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
- Install new gaskets.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
-
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 an 12 mm (0.47 in) bead 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)
- Install the valve cover and tighten the bolts.
Torque: 1-3: 89 lb.in (10 Nm) 4-17: 133 lb.in (15 Nm)
- Install a new coolant pump O-ring seal and lubricate with clean engine coolant.
- Install the coolant pump and bolts.
Torque:Stage 1: 177 lb.in (20 Nm)
Stage 2: 60 deg.
- Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.
-
NOTE: Only the plate from 303-335 should be used.
Using the special tools, install the new crankshaft front oil seal. Use Special Service Tool: 303-1531 Installer, Front Crank Seal and Damper., 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal.
-
- Clean off any residual sealer from the Woodruff key slot and the Woodruff key on the crankshaft (not shown).
-
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 gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Material
: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
- 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.
- With the aid of an assistant, use the Strap Wrench to install a new crankshaft pulley bolt and the original washer. Use the General Equipment: Strap Wrench
Torque:Stage 1: 103 lb.ft (140 Nm)
Stage 2: Loosen: 360 deg.
Stage 3: 74 lb.ft (100 Nm)
Stage 4: 90 deg.
-
- Install the A/C compressor drive belt tensioner and the bolt.
Torque: 18 lb.ft (25 Nm)
- Install the coolant pump pulley and the bolts.
Torque: 18 lb.ft (25 Nm)
- Install the A/C compressor drive belt tensioner and the bolt.
-
- Install the LH ignition coil-on-plugs.
- Install the LH ignition coil-on-plug retaining bolts.
Torque: 89 lb.in (10 Nm)
-
NOTE: Only rotate the crankshaft clockwise or damage to the engine may occur.NOTE: The drive lobe for the high-pressure fuel pump must be at bottom dead center for the high-pressure fuel pump installation.
With the help of an assistant, using the crankshaft pulley bolt, turn the crankshaft clockwise until the high-pressure fuel pump drive lobe is at bottom dead center.
- Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and all of the roller tappet.
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NOTE: The roller tappets roller goes down towards the camshaft.NOTE: Align the notch on the high-pressure fuel pump tappet and with the groove in the high-pressure fuel pump drive unit bore.
Install the high-pressure fuel pump roller tappet.
- Install a new high-pressure fuel pump O-ring seal. Lubricate with clean engine oil.
- Install the high-pressure fuel pump, then install the mounting nuts finger tight. Alternately tighten each high-pressure fuel pump nut one complete revolution until seated. Tighten the fuel high-pressure fuel pump nuts in the following 2 stages.
Torque:Stage 1: Tighten to : 89 lb.in (10 Nm)
Stage 2: Tighten an additional : 30 deg.
- Install the spacer.
-
NOTE: In stage 7, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 37 lb ft (50 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.NOTE: Do not use oil on the threads.NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.NOTE: Make sure that a new high-pressure fuel tube is installed.
Install the high-pressure fuel tube and retainers, tighten the high-pressure fuel tube flare nuts and retainers finger tight.
Torque:Stage 1: Tighten the upper high-pressure fuel tube bolt to : 89 lb.in (10 Nm)
Stage 2: Tighten the upper high-pressure fuel tube bolt an additional : 30 deg.
Stage 3: Tighten the lower high-pressure fuel tube bolt to : 89 lb.in (10 Nm)
Stage 4: Tighten the lower high-pressure fuel tube bolt an additional : 30 deg.
Stage 5: Tighten the high-pressure fuel tube flare nuts to : 71 lb.in (8 Nm)
Stage 6: Tighten the high-pressure fuel tube flare nuts to : 89 lb.in (10 Nm)
Stage 7: Tighten the high-pressure fuel tube flare nuts an additional : 25 deg.
- Install the high-pressure fuel tube shield and the fasteners.
Torque: 89 lb.in (10 Nm)
-
NOTE: The high-pressure fuel pump supply tube must be installed with the Oetiker® clamp end installed to the port fuel rail; if it is installed backwards a check valve will prevent the engine from running properly.
Connect the high-pressure fuel pump fuel feed quick release coupling. Follow the directions for the quick release coupling type 2. Refer to: Quick Release Coupling .
-
- Install the RH ignition coil-on-plugs.
- Install the RH ignition coil-on-plug retaining bolts.
Torque: 89 lb.in (10 Nm)
-
NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Install the fuel injection pump noise insulator and the retainer.
- Install the KSs and the bolts.
Torque: 177 lb.in (20 Nm)
-
- Install the KS harness onto the engine.
- Attach the wiring harness retainers.
- Connect the KS electrical connectors.
- Install the wiring harness and the nut.
Torque: 89 lb.in (10 Nm)
-
- Connect the engine wiring harness electrical connectors.
- Attach the engine wiring harness retainers.
-
- Connect the engine wiring harness electrical connectors.
- Slide the insulator onto s the electrical connector.
- Position the RFI capacitor and install the bolt.
Torque: 89 lb.in (10 Nm)
- Attach the engine wiring harness retainer.
-
- Connect the engine wiring harness electrical connectors.
- Attach the engine wiring harness retainers.
-
- Connect the engine wiring harness electrical connectors.
- Attach the engine wiring harness retainers.
- Attach the engine wiring harness retainers.
-
- Connect the engine wiring harness electrical connectors.
- Slide the insulator onto the electrical connector.
- Attach the engine wiring harness retainers.
- Follow directions to connect the quick release coupling type 3. Install the crankcase vent tube. Refer to: Quick Release Coupling
.
- Install new studs.
Torque: 18 lb.ft (25 Nm)
- Install a new gasket.
- Install the exhaust manifold.
- Install the new nuts.
Torque:Stage 1: 18 lb.ft (24 Nm)
Stage 2: 24 lb.ft (32 Nm)
- Install the new nuts.
- Install the heat shield and bolts.
Torque: 106 lb.in (12 Nm)
-
NOTE: Some replacement exhaust manifolds do not come with studs.
If necessary, install new studs.
Torque: 30 lb.ft (40 Nm)
- Install new studs.
Torque: 18 lb.ft (25 Nm)
- Install a new gasket.
- Install the exhaust manifold.
- Install the new nuts.
Torque:Stage 1: 18 lb.ft (24 Nm)
Stage 2: 24 lb.ft (32 Nm)
- Install the new nuts.
- Install the heat shield and bolts.
Torque: 106 lb.in (12 Nm)
-
NOTE: Some replacement exhaust manifolds do not come with studs.
If necessary, install new studs.
Torque: 30 lb.ft (40 Nm)
- Install the A/C compressor and the bolts.
Torque: 18 lb.ft (25 Nm)
- Rotate the tensioner clockwise and remove the A/C compressor drive belt.
-
NOTE: If a new RH engine mount is installed, remove the 2 studs prior to positioning the engine in the vehicle.
Install the RH engine mount and the new bolts.
Torque: 55 lb.ft (75 Nm)
- Install the LH engine mount-to-cylinder block bracket and the new bolts.
Torque: 55 lb.ft (75 Nm)
- Lubricate the O-ring seal with clean engine oil.
-
- Install the oil level indicator tube.
- Install the nuts.
Torque: 71 lb.in (8 Nm)
- Install the oil level indicator.
- 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
- Lubricate the seal bore and the seal lips with clean engine oil.
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- 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.
- 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.
- Inspect the engine block dowels. If the dowels are damaged or missing, install new engine block dowels.