Section 9 (Engine - 2.5L DURATEC (125KW/170PS)): Assembly: Engine

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

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F
Courtesy of FORD MOTOR COMPANY	303-1247VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM
Courtesy of FORD MOTOR COMPANY	303-1417 Tool, Crank Sensor Alignment TKIT-2008ET-FLM TKIT-2008ET-ROW
Courtesy of FORD MOTOR COMPANY	303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-FLM TKIT-1988-F TKIT-1988-LM
Courtesy of FORD MOTOR COMPANY	303-465 Tool, Camshaft Align Timing TKIT-1994-LMH/MH2 TKIT-1994-FH/FMH/FLMH
Courtesy of FORD MOTOR COMPANY	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW
Round-Ended Steel Rule
Piston Ring Compressor

Materials 

1. Install the oil squirters.

   Torque

   : 35 lb.in (4 Nm)

   Courtesy of FORD MOTOR COMPANY

2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.

   Courtesy of FORD MOTOR COMPANY

3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.

   Courtesy of FORD MOTOR COMPANY

4. Tighten the bolts in sequence shown in illustration.

   Torque

   :Stage 1: 44 lb.in (5 Nm)

   Stage 2: 18 lb.ft (25 Nm)

   Stage 3: 90°

   Courtesy of FORD MOTOR COMPANY

5. Measure each crankshaft block main bearing bore diameter.

   Courtesy of FORD MOTOR COMPANY

6. Using the chart, select the crankshaft main bearings.

   Courtesy of FORD MOTOR COMPANY

7. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

   Using the original connecting rod cap bolts, install the connecting caps and the bolts.

   Torque

   :Stage 1: 89 lb.in (10 Nm)

   Stage 2: 21 lb.ft (29 Nm)

   Stage 3: 90°

   Courtesy of FORD MOTOR COMPANY

8. • Measure the connecting rod large end bore in 2 directions.
   • Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod caps. Discard the bolts.

   Courtesy of FORD MOTOR COMPANY

9. • Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
   • Record the smallest measurement for each connecting rod journal.

   Courtesy of FORD MOTOR COMPANY

10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

    Courtesy of FORD MOTOR COMPANY

11. Remove the bolts in sequence shown in illustration and the main bearing beam. Discard the bolts.

    Courtesy of FORD MOTOR COMPANY

12. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
    NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
    NOTE: The center bulkhead is the thrust bearing.

    Lubricate with clean engine oil and install the upper crankshaft main bearings.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

13. NOTE: If reusing the crankshaft main bearings, install them in the original positions and orientation as noted during disassembly.

    Lubricate with clean engine oil and install the lower crankshaft main bearings.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

14. NOTE: Lubricate the journals on the crankshaft with clean engine oil.

    Lubricate with clean engine oil and install the crankshaft.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

15. Lubricate the main bearing beam with clean engine oil.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

16. Install the main bearing beam flush.

    Courtesy of FORD MOTOR COMPANY

17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
    NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

    Install the new bolts and tighten in sequence shown in illustration in 3 stages.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Torque

    :Stage 1: 44 lb.in (5 Nm)

    Stage 2: 18 lb.ft (25 Nm)

    Stage 3: 90°

    Fig 1: Main Bearing Beam Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
18. • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge with Holding Fixture.

      Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • Acceptable crankshaft end play is 0.22-0.45 mm (0.008-0.018 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.

    Courtesy of FORD MOTOR COMPANY

19. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

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

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

20. NOTE: The piston compression upper and lower rings should be installed with the paint mark on the outside diameter circumference of the ring to be positioned on the right side of the ring gap. The lower compression ring needs to be installed with the undercut side downward.
    NOTE: The arrow on the top of the piston indicates the front of the engine.
    1. Upper compression ring gap location.
    2. Lower compression ring gap location.
    3. Upper oil control segment ring gap location.
    4. Lower oil control segment ring gap location.

    Courtesy of FORD MOTOR COMPANY

21. • Lubricate the pistons with clean engine oil.

      Material

      : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    • 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: Make sure the piston arrow on top is facing toward the front of the engine.

      Using a piston ring compressor, install the pistons. Use the General Equipment: Piston Ring Compressor

    Courtesy of FORD MOTOR COMPANY

22. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180° and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
    NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

    Install the connecting rod caps and the new bolts. Tighten in 3 stages.

    Torque

    :Stage 1: 89 lb.in (10 Nm)

    Stage 2: 21 lb.ft (29 Nm)

    Stage 3: 90°

    Courtesy of FORD MOTOR COMPANY

23. NOTE: Only rotate the crankshaft clockwise.
    1. Install the special tool.

       Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

    2. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC.

    Courtesy of FORD MOTOR COMPANY

24. Install the adjustment shims in their original positions on the seat faces of the balancer unit. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.

    Courtesy of FORD MOTOR COMPANY

25. Install the bolts and tighten in sequence shown in illustration in 2 stages.

    Torque

    :Stage 1: 18 lb.ft (25 Nm)

    Stage 2: 38 lb.ft (52 Nm)

    Fig 2: Balancer Unit Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
26. NOTE: Only rotate the crankshaft clockwise.
    • Remove the special tool.

      Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

    • Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.

    Courtesy of FORD MOTOR COMPANY

27. NOTE: Only rotate the crankshaft clockwise.
    1. Install the special tool. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    2. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC.
    3. Remove the special tool. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

    Courtesy of FORD MOTOR COMPANY

28. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10°, 30°, 100°, 190°, 210° and 280°. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown in illustration. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration.
    • Position as shown. Measure the gear backlash.

      Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    • Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10°, 30°, 100°, 190°, 210° and 280°.
    • Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
    • If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. Refer to: Valve Clearance Adjustment .

    Courtesy of FORD MOTOR COMPANY

29. NOTE: Only rotate the crankshaft clockwise.
    1. Install the special tool.

       Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

    2. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.

    Courtesy of FORD MOTOR COMPANY

30. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
31. NOTE: Make sure that the mating faces are clean and free of foreign material.

    Install the oil pump and the bolts. Tighten in sequence shown in illustration in 2 stages.

    Torque

    :Stage 1: 89 lb.in (10 Nm)

    Stage 2: 177 lb.in (20 Nm)

    Courtesy of FORD MOTOR COMPANY

32. Using a new gasket, install the oil pickup tube and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

33. NOTE: Make sure that the mating faces are clean and free of foreign material.
    • Using the special tool, position the crankshaft rear oil seal onto the crankshaft.

      Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.

    • Install the bolts and tighten in sequence shown in illustration.

      Torque

      : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

34. Clean all mating surfaces.

    Material

    : Motorcraft® Silicone Gasket Remover / ZC-30-A

    Material

    : Motorcraft® Metal Surface Prep Wipes / ZC-31-B

35. NOTE: Make sure that the mating faces are clean and free of foreign material.
    NOTE: The component must be installed within 10 minutes of applying the sealant.

    Apply a 3 mm bead of silicone sealant.

    Material

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

    Courtesy of FORD MOTOR COMPANY

36. NOTE: Only tighten the bolts finger tight at this stage.

    Install the oil pan and the bolts finger tight.

    Courtesy of FORD MOTOR COMPANY

37. Using a straight edge, align the front surface of the oil pan flush with the front surface of the engine block.

    Use the General Equipment: Round-Ended Steel Rule

    Courtesy of FORD MOTOR COMPANY

38. Tighten the bolts in sequence shown in illustration.

    Torque

    : 177 lb.in (20 Nm)

    Courtesy of FORD MOTOR COMPANY

39. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

    Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.

    Material

    : Motorcraft® Metal Surface Prep Wipes / ZC-31-B

40. NOTE: Dowels must be fully seated in the cylinder block.

    Install the cylinder head alignment dowels.

    Courtesy of FORD MOTOR COMPANY

41. NOTE: Make sure that the mating faces are clean and free of foreign material.
    NOTE: The component must be installed within 10 minutes of applying the sealant.

    Apply a 6 mm bead of silicone sealant.

    Material

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

    Courtesy of FORD MOTOR COMPANY

42. Install a new cylinder head gasket.

    Courtesy of FORD MOTOR COMPANY

43. NOTE: Make sure that new bolts are installed.

    Install the cylinder head, bolts and tighten in sequence shown in illustration in 5 stages.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Torque

    :Stage 1: 62 lb.in (7 Nm)

    Stage 2: 133 lb.in (15 Nm)

    Stage 3: 33 lb.ft (45 Nm)

    Stage 4: 90°

    Stage 5: 90°

    Courtesy of FORD MOTOR COMPANY

44. Lubricate with clean engine oil and install the valve tappets.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

45. NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180° out of position, can cause severe damage to the valves and pistons.

    Lubricate the camshaft with clean engine oil and position in the cylinder head.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

46. 1. NOTE: Only tighten the bolts finger tight at this stage.

       Install the camshaft caps and bolts.

    2. Tighten 2 turns at a time in sequence shown in illustration in 2 stages.

       Torque

       :Stage 1: 62 lb.in (7 Nm)

       Stage 2: 142 lb.in (16 Nm)

    Courtesy of FORD MOTOR COMPANY

47. Install the VCT oil control solenoid and the bolt.

    Torque

    : 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

48. NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    Identify crankshaft sprocket type.

    1. Early build engine - Flat faced sprocket (requires diamond washers).
    2. Late build engine - Laser etched sprocket (does

       NOT  require diamond washers).

    Courtesy of FORD MOTOR COMPANY

49. NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
    NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, install the diamond washer.

    Courtesy of FORD MOTOR COMPANY

50. Install the crankshaft sprocket.

    Courtesy of FORD MOTOR COMPANY

51. Install the oil pump drive chain, sprocket and bolt.

    Torque

    : 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

52. 1. Install the timing chain tensioner and the shoulder bolts.

       Torque

       : 89 lb.in (10 Nm)

    2. Push the tensioner spring down and position the spring under the shoulder bolt.

    Courtesy of FORD MOTOR COMPANY

53. NOTE: The special tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

    Install the special tool. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.

    Courtesy of FORD MOTOR COMPANY

54. NOTE: Only tighten the bolts finger tight at this stage.

    Install the camshaft sprockets and the bolts.

    Courtesy of FORD MOTOR COMPANY

55. Install the timing chain.

    Courtesy of FORD MOTOR COMPANY

56. Install the tensioner arm, timing chain guide and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

    NOTE: If equipped with aluminum timing chain tensioner.
    NOTE: If the timing chain tensioner plunger is not pinned in the compressed position, follow the next step.
57. Reset the timing chain tensioner.
    1. Position the timing chain tensioner in a soft-jawed vise.
    2. Spread the ends of the ratchet wire clip apart.
    3. Using the soft-jawed vise, compress the plunger to the reset position.
    4. Install a locking pin in the 2 holes of the timing chain tensioner body to hold the plunger in place.

    Courtesy of FORD MOTOR COMPANY

58. NOTE: If equipped with aluminum timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.
    1. Install the timing chain tensioner and the bolts.

       Torque

       : 89 lb.in (10 Nm)

    2. Remove the locking pin.

    Courtesy of FORD MOTOR COMPANY

    NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
59. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

    Using the edge of a vise, compress the timing chain tensioner plunger.

    Courtesy of FORD MOTOR COMPANY

60. Using a small pick, push back and hold the ratchet mechanism.

    Courtesy of FORD MOTOR COMPANY

61. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

    Courtesy of FORD MOTOR COMPANY

62. Install a locking pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

    Courtesy of FORD MOTOR COMPANY

63. NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

    Install the timing chain tensioner and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

64. NOTE: If equipped with cast iron timing chain tensioner.

    Remove the locking pin.

    Courtesy of FORD MOTOR COMPANY

65. NOTE: Use an open-ended wrench to prevent the component from turning.

    Tighten the camshaft sprockets in 2 stages.

    Torque

    :Stage 1: 30 lb.ft (40 Nm)

    Stage 2: 60°

    Courtesy of FORD MOTOR COMPANY

66. NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Clean all mating surfaces.

    Material

    : Motorcraft® Silicone Gasket Remover / ZC-30-A

    Material

    : Motorcraft® Metal Surface Prep Wipes / ZC-31-B

67. NOTE: The component must be installed within 10 minutes of applying the sealant.
    NOTE: Make sure that the mating faces are clean and free of foreign material.

    Apply beads of silicone sealant that are 15 mm (0.078 in) in diameter across the cylinder head and cylinder block joint areas.

    Material

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

    Courtesy of FORD MOTOR COMPANY

68. NOTE: The component must be installed within 10 minutes of applying the sealant.
    NOTE: Make sure that the mating faces are clean and free of foreign material.

    Apply a 3mm bead of silicone sealant to the outside sealing surfaces of the engine front cover. Apply a 2mm bead of silicone sealant to the inside sealing surfaces.

    Material

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

    Courtesy of FORD MOTOR COMPANY

69. Install the engine front cover and the bolts. Tighten in sequence shown in illustration.

    Torque

    :Stage 1: Bolts 1 - 3: 35 lb.ft (48 Nm)

    Stage 2: Bolts 4 - 7: 89 lb.in (10 Nm)

    Stage 3: Bolt 8: 18 lb.ft (25 Nm)

    Stage 4: Bolts 9 - 13: 89 lb.in (10 Nm)

    Stage 5: Bolt 14: 35 lb.ft (48 Nm)

    Stage 6: Bolts 15 - 23: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

70. NOTE: Clean the coolant pump mating surfaces.
    NOTE: Install a new O-ring seal.
    • Install and lubricate the coolant pump O-ring seal with clean engine coolant.

      Material

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

    • Install the coolant pump and the bolts.

      Torque

      : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

71. NOTE: Apply clean engine oil on the seal before installing.

    Using the special tool, install the crankshaft front seal.

    Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

72. NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
    NOTE: Early build engines are equipped with a diamond washers on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, install the diamond washer onto the crankshaft.

    Courtesy of FORD MOTOR COMPANY

73. NOTE: Apply clean engine oil on the seal before installing.
    NOTE: Do not install the crankshaft pulley bolt at this time.

    Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.

    Material

    : Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

74. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

    Install a standard M6 X 18 mm bolt through the crankshaft pulley and thread it into the engine front cover.

    Courtesy of FORD MOTOR COMPANY

75. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

    Using a crank damper holding tool, tighten the crankshaft pulley.

    Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.

    Torque

    :Stage 1: 74 lb.ft (100 Nm)

    Stage 2: 90°

    Courtesy of FORD MOTOR COMPANY

76. Remove the standard M6 X 18 mm bolt.

    Courtesy of FORD MOTOR COMPANY

77. Remove the special tool. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

    Courtesy of FORD MOTOR COMPANY

78. Remove the special tool. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.

    Courtesy of FORD MOTOR COMPANY

79. NOTE: Only rotate the crankshaft clockwise.

    Rotate the crankshaft clockwise one and three-fourths turns.

    Courtesy of FORD MOTOR COMPANY

80. NOTE: Only rotate the crankshaft clockwise.
    1. Install the special tool. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    2. Rotate the crankshaft slowly until the crankshaft stops.

    Courtesy of FORD MOTOR COMPANY

81. NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

    Install a standard M6 X 18 mm bolt. Check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected.

    Courtesy of FORD MOTOR COMPANY

82. NOTE: The special tool can only be installed if the valve timing is correct.

    If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.

    Courtesy of FORD MOTOR COMPANY

83. NOTE: The special tool can only be installed if the valve timing is correct.

    Remove the special tool. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.

    Courtesy of FORD MOTOR COMPANY

84. NOTE: Only tighten the bolts finger tight at this stage.

    Install the CKP sensor and the bolts.

    Torque

    : 62 lb.in (7 Nm)

    Courtesy of FORD MOTOR COMPANY

85. Install the special tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel.

    Use Special Service Tool: 303-1417 Tool, Crank Sensor Alignment.

    Torque

    : 62 lb.in (7 Nm)

    Courtesy of FORD MOTOR COMPANY

86. Remove the standard M6 X 18 mm bolt.

    Courtesy of FORD MOTOR COMPANY

87. Remove the special tool. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

    Courtesy of FORD MOTOR COMPANY

88. Install the engine plug bolt.

    Torque

    : 177 lb.in (20 Nm)

    Courtesy of FORD MOTOR COMPANY

89. If removed, using the special tools, install the VCT oil control solenoid seal.

    Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer., 205-153 (T80T-4000-W) Handle.

    Courtesy of FORD MOTOR COMPANY

90. Inspect and if necessary, install new valve cover.

    Courtesy of FORD MOTOR COMPANY

91. NOTE: Make sure that the mating faces are clean and free of foreign material.

    Apply a 6 mm bead of silicone sealant.

    Material

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

    Courtesy of FORD MOTOR COMPANY

92. NOTE: The component must be installed within 10 minutes of applying the sealant.

    Install the valve cover and tighten the fasteners in sequence shown in illustration.

    Torque

    : 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY