Engine Accessories

WARNING: This page is about a different variant/trim than selected.

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

Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F
Lifting Bracket
Mounting Stand
Hose Clamp Remover/Installer

Materials

Name	Specification
Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil XO-5W20-Q1SP	WSS-M2C945-B1
Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A

If equipped, install the block heater.
Torque

: 30 lb.ft (40 Nm)

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Inspect the crankcase vent oil separator gasket and replace if necessary.

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

Install the crankcase vent oil separator and the bolts.

Torque

: 89 lb.in (10 Nm)

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Inspect the thermostat housing gasket and replace if necessary.

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Install the thermostat housing and the bolts.
Torque

: 89 lb.in (10 Nm)

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NOTE: Make sure that the component is installed to the position noted before removal.

Install the knock sensor and the bolt.

Torque

: 177 lb.in (20 Nm)

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Install the water by pass hose and connect the clamps.
Use the General Equipment: Hose Clamp Remover/Installer

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Install the EGR tube.
Torque

: 41 lb.ft (55 Nm)

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NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Inspect the intake manifold gaskets and replace if necessary.

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Position the intake manifold and connect the crankcase vent oil separator tube.

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NOTE: Install all the bolts finger tight before final tightening.

Position back the intake manifold and install the bolts. Tighten the bolts in the sequence shown in illustration.

Torque: 177 lb.in (20 Nm)

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NOTE: Make sure that new components are installed.

Install the fuel injector retaining clips and the fuel injector O-ring seals. Lubricate the fuel injector O-ring seals.

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

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Install the fuel injectors into the fuel rail.

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NOTE: Only use moderate force.

Install the fuel rail and the bolts.

Torque: 17 lb.ft (23 Nm)

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Install the radio capacitor and the nut.
Torque: 89 lb.in (10 Nm)

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Install the fuel rail insulator.

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Install the engine wire harness and connect the harness retainer.

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Connect the EGR valve electrical connector.

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Position the bracket and install the nuts.
Torque: 80 lb.in (9 Nm)

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Connect the electrical connector and wire retainers.

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Connect the electrical connectors.

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Connect the wire harness retainer to the intake manifold.

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Connect the fuel injector electrical connectors and the wiring harness retainers to the fuel rail.

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Position the electrical connector and connect the retainer.

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Install the oil level indicator.

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Inspect the ignition coil boots.

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NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the ignition coil-on-plugs and the bolts.

Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

Torque: 71 lb.in (8 Nm)

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Connect the CHT sensor electrical connector and position the boot on the CHT sensor.

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Connect the CMP sensor electrical connector and the ignition coil-on-plugs electrical connectors.

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Connect the VCT oil control solenoid electrical connector.

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Connect the electrical connector and wire retainers to the intake manifold.

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Connect the wire retainers.

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Connect the crankshaft position sensor electrical connector and the wire retainer.

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Install the crankcase vent tube. Refer to: Quick Release Coupling .

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Install the coolant pump pulley and the bolts.
Torque: 177 lb.in (20 Nm)

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Install the idler pulley and the bolt.
Torque: 97 lb.in (11 Nm)

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Install the accessory drive belt tensioner and the bolts.
Torque: 18 lb.ft (25 Nm)

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Install the floor crane.
Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

Install the General Equipment: Lifting Bracket

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Remove the engine mounting stand.
Remove the General Equipment: Mounting Stand

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- Using the special tool, install the flexplate and the new bolts.
  Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Tighten the bolts in the sequence shown in illustration. Remove the special tool.
  Torque:
  
  Stage 1: 37 lb.ft (50 Nm)
  
  Stage 2: 59 lb.ft (80 Nm)
  
  Stage 3: 83 lb.ft (112 Nm)

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