Section 141 (Engine - 3.5L ECOBOOST (235KW/320PS)): Assembly: Engine

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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	205-142 (T80T-4000-J)Installer, Differential Bearing Cone
Courtesy of FORD MOTOR COMPANY	205-150 (T80T-4000-S)Installer, Spindle Bearing
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W)Handle
Courtesy of FORD MOTOR COMPANY	303-102Installer, Crankshaft Pulley
Courtesy of FORD MOTOR COMPANY	303-1247VCT Spark Plug Tube Seal Remover and Installer
Courtesy of FORD MOTOR COMPANY	303-1248Camshaft holding tools
Courtesy of FORD MOTOR COMPANY	303-1250Seal Installer, Rear Main
Courtesy of FORD MOTOR COMPANY	303-1251Installer, Front Seal
Courtesy of FORD MOTOR COMPANY	303-1530Tool, Chain Tensioner Hold Down
Courtesy of FORD MOTOR COMPANY	303-1567Sizer, Teflon Seal
Courtesy of FORD MOTOR COMPANY	303-335 (T88T-6701-A)Installer, Front Cover Oil Seal
Courtesy of FORD MOTOR COMPANY	307-399Alignment Pins, Transmission Fluid Pump
Courtesy of FORD MOTOR COMPANY	310-207Installer, Fuel Injector Seal Assembly
Feeler Gauge
Strap Wrench
Floor Crane
Mounting Stand
Hose Clamp Remover/Installer
Round-Ended Steel Rule
Piston Ring Compressor

Materials

Name	Specification
Grease - High Temperature	WSS-M1C267-A1
RTV silicone sealant	WSE-M4G323-A6
gasket remover	-
Anti-Seize Lubricant	-
Flange Sealant	WSS-M2G348-A11
metal cleaner	-
grease - silicone	ESA-M1C200-AESE-M1C171-A

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components. These inspections/measurements will aid in determining if the engine components will require replacement. Refer to: ENGINE SYSTEM - GENERAL INFORMATION

NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed. Refer to: Variable Camshaft Timing (VCT) Unit

Using a hexagonal screwdriver, install the piston oil cool valves.
Torque: 4 Nm

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NOTE: This step is for selecting the correct main bearings.

NOTE: The #1 main bearing is at the front of the engine block.
- Select the crankshaft main bearings for each crankshaft journal.
- Record the code that is on the cylinder block face.
- Record the code that is on the crankshaft flange.
- The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.
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NOTE: This chart is continued in the next step.

NOTE: This chart is for selecting main bearings 1 and 4 only.
- Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4.
- 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 "M" and the crankshaft code letter is "M", the correct bearing grade for this main bearing is a "2" for the upper bearing and a "2" for the lower bearing.
- Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
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NOTE: This chart is for selecting main bearings 1 and 4 only.

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NOTE: This chart is continued in the next step.

NOTE: This chart is for selecting main bearings 2 and 3 only.
- Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3.
- 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 for the No. 2 crankshaft main bearing.
- As an example, if the engine block code letter is "N" and the crankshaft code letter is "H", the correct bearing grade for this main bearing is "2".
- Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
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NOTE: This chart is for selecting main bearings 2 and 3 only.

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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 rod caps and bolts.

Torque: Stage 1: 23 Nm Stage 2: 43 Nm Stage 3: 90deg.

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Measure the connecting rod large end bore in 2 directions.

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- Remove the bolts and the rod cap.
- Discard the bolts.
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Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.

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

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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.

Lubricate the upper crankshaft main bearings with clean engine oil and install in the cylinder block. Refer to: Specifications .

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NOTE: Do not install the upper thrust bearings until the crankshaft is installed.

NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.

Install the crankshaft. Refer to: Specifications .

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NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.

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NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.

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Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Check seating and squareness of the bearings to make sure of proper seating in caps. Refer to: Specifications .

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NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps.

NOTE: Early build engine shown, late build engine similar.

Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.

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NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.

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NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps.

NOTE: Early build engine shown, late build engine similar.

Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.

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NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps.

NOTE: Early build engine shown, late build engine similar.

NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.

Tighten the main bearing bolts.

Torque: Early build engines: Stage 1: 33 Nm Stage 2: 135deg. Late build engines: Stage 3: 27 Nm Stage 4: 180deg.

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Install the new main bearing cap side bolts.
Torque: Stage 1: 45 Nm Stage 2: 90deg.

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1. Position the crankshaft to the rear of the cylinder block.Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
2. Zero the Dial Indicator Gauge.
3. Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play.
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NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
- Prepare the connecting rod and cap.
- Insert the new bolts in the rod cap.
- Insert the upper and lower rod bearings into the rod and cap.
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NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring face pointing up toward the top of the piston.

NOTE: The arrow on the top of the piston indicates the front of the engine.
1. Center line of the piston parallel to the wrist pin bore.
2. Upper compression ring gap location.
3. Upper oil control segment ring gap location.
4. Lower oil control segment ring gap location.
5. Expander ring and lower compression ring gap location.
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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 pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.

NOTE: Make sure the piston rings are positioned to specifications for installation. Refer to: Piston

NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.

NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.

Using the Piston Ring Compressor, install the piston and connecting rod assemblies. Repeat until all 6 piston assemblies are installed.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: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation.

Install the connecting rod cap and the new bolts.

Torque: Stage 1: 23 Nm Stage 2: 43 Nm Stage 3: 90deg.

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NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps.

NOTE: Early build engine shown, late build engine similar.

Install the main bearing cap support brace and the new bolts.

Torque: Early build engines : Stage 1: 24 Nm Stage 2: 180deg. Late build engines : Stage 3: 27 Nm Stage 4: 225deg.

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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 crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.

Apply a 4 mm (0.16 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.

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Lubricate the crankshaft with clean engine oil.

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Verify the crankshaft rear seal lip is not rolled.

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- Lubricate the special tool with clean engine oil and install.Install Special Service Tool: 303-1250 Seal Installer, Rear Main.
- NOTE: Inspect and ensure that the crankshaft rear seal lip is not rolled before proceeding to step 31.
  
  Install the crankshaft rear seal.
- Remove the special tool.Remove Special Service Tool: 303-1250 Seal Installer, Rear Main.
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Install the crankshaft rear seal and the bolts.
Torque: 10 Nm

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Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
Install the oil pump and the bolts.
Torque: 10 Nm

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Install a new oil pump screen and the pickup tube O-ring seal.

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Install the oil pump screen and the pickup tube and the bolts.
Torque: 10 Nm

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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

Apply a 5 mm (0.20 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan.

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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

Apply a 9 mm (0.35 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.

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Install the oil pan and bolts.
Torque: Stage 1: 3 Nm Stage 2: Loosen: : 180deg.

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Using a straight edge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.Use the General Equipment: Round-Ended Steel Rule

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Tighten the bolts in the sequence.
Torque: 3 Nm

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Install the remaining oil pan bolts.
Torque: Stage 1: Tighten bolts 1 through 14 to : 24 Nm Stage 2: Tighten bolt 10 an additional : 90deg. Stage 3: Tighten bolts 15 and 16 to : 10 Nm

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Install the stud bolt.
Torque: 3 Nm

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Install the channel cover plate and the bolts.
Torque: Stage 1: 10 Nm Stage 2: 45deg.

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Install the KS and the bolts.
Torque: 20 Nm

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Inspect for any debri before installing the RH water jacket.

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Install the RH water jacket flush with the bottom of the block.

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Install the RH cylinder head gasket.

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NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

Install the RH cylinder head and the new bolts.

Torque: Stage 1: 20 Nm Stage 2: 35 Nm Stage 3: 90deg. Stage 4: 90deg. Stage 5: 45deg.

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Install the new RH M6 bolt.
Torque: 10 Nm

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Install the RH lift eye.
Torque: 28 Nm

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Vehicles with cast iron exhaust manifold
Install the RH exhaust manifold gasket and hand start new studs.
Torque: 13 Nm

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Instal the RH exhaust manifold and new nuts.
Torque: Stage 1: 19 Nm Stage 2: 25 Nm

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Vehicles with stainless steel exhaust manifold
This step is only necessary if the original cast iron exhaust manifold is being replaced by a stainless steel exhaust manifold.Using a bottoming tap, clean the threads of the stud holes that were not used for the original exhaust manifold.

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Install the RH exhaust manifold gasket and hand start new studs.
Torque: 13 Nm

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Instal the RH exhaust manifold and new nuts.
Torque: Stage 1: 19 Nm Stage 2: 22 Nm

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All vehicles
Inspect for any debri before installing the LH water jacket.

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Install the LH water jacket flush with the bottom of the block.

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Install the LH cylinder head gasket.

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NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

Install the LH cylinder head and the new bolts.

Torque: Stage 1: 20 Nm Stage 2: 35 Nm Stage 3: 90deg. Stage 4: 90deg. Stage 5: 45deg.

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Install the new M6 bolt.
Torque: 10 Nm

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Install the new LH lift eye and bolts.
Torque: 28 Nm

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Vehicles with cast iron exhaust manifold
Install the LH exhaust manifold gasket and hand start the new studs.
Torque: 13 Nm

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Install the LH exhaust manifold and new nuts.
Torque: Stage 1: 19 Nm Stage 2: 25 Nm

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Vehicles with stainless steel exhaust manifold
This step is only necessary if the original cast iron exhaust manifold is being replaced by a stainless steel exhaust manifold.Using a bottoming tap, clean the threads of the stud holes that were not used for the original exhaust manifold.

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Install the LH exhaust manifold gasket and hand start the new studs.
Torque: 13 Nm

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Install the LH exhaust manifold and new nuts.
Torque: Stage 1: 19 Nm Stage 2: 22 Nm

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All vehicles
1. Remove and discard the fuel injector O-ring seals.
2. NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the NEW fuel injector support rings.
  
  Remove and discard the fuel injector support rings.
3. Inspect the inlet stopper, if it is damaged or comes off then discard the inlet stopper. The inlet stopper is not needed for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.
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NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injector.

NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
1. Pull the lower Teflon® seal away from the injector.
2. Carefully cut and discard the lower fuel injector Teflon® seal.
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1. Install the Teflon® Seal Guide onto the fuel injector tip.Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
  
  NOTE: Make sure that NEW lower fuel injector Teflon® seals are installed.
  
  Install the NEW Teflon® seals onto the Teflon® Seal Guide, using the Pusher Tool, slide the Teflon® seals along the Teflon® Seal Guide.
3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors.Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
4. Remove the special tools.
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NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
1. Massage and warm the Teflon® seal with your fingers before the Teflon® seal sizer tool is installed. This will aid in installing the Teflon® seal sizer tool.
2. NOTE: The beveled opening of the Teflon® seal sizer tool goes away from the seal.
  
  Position the Teflon® seal sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® seal sizer tool 180 degrees.Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
3. Once the Teflon® seal sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® seal sizer tool.
4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
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NOTE: Make sure that NEW fuel injector support rings and NEW fuel injector O-ring seals are installed.
1. Install the new fuel injector O-rings. The O-rings are pre-lubricated, NO ADDITIONAL lubricant is required.
2. NOTE: The NEW the fuel injector support rings must be installed in the correct orientation with the wide surface area facing up against the fuel injector O-ring seals. Improperly installed support rings may cause the fuel system to leak.
  
  Install the NEW the fuel injector support rings.
3. Inspect the inlet stopper, if it is damaged or comes off then discard the inlet stopper. The inlet stopper is not needed for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.
4. The upper side of the support ring has the wide surface area.
5. Fuel injector support ring.
6. The lower side of the support ring has the narrow surface area.
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Install the NEW fuel injector clips.

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NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.

NOTE: The anti-rotation finger of the new fuel injector clip must slip into the groove of the fuel rail cup.

Install the fuel injectors to the fuel rail.

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Connect the fuel injector electrical connectors.

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Apply grease to the tip of the fuel injectors.
Material: Grease - High Temperature (WSS-M1C267-A1)

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Apply grease to the top of the fuel injector bores.
Material: Grease - High Temperature (WSS-M1C267-A1)

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NOTE: When installing the fuel rails install the right side fuel rail first.

NOTE: Make sure that new fuel rail bolts are installed.

Push down on the fuel rail above the injectors. Tighten the fuel rail bolts in the sequence shown.

Torque: Stage 1: 10 Nm Stage 2: 45deg.

Fig 1: Fuel Rail Tightening Sequence
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NOTE: The valve tappets must be installed in their original positions.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

NOTE: RH shown, LH similar.

Install the valve tappets. Refer to: Specifications .

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Install the RH primary timing chain guide and the bolt.
Torque: 10 Nm

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NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

Position the crankshaft dowel pin in the 9 o'clock position.

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NOTE: Coat the camshafts with clean engine oil prior to installation.

Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral position as shown. Refer to: Specifications .

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NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

Position the RH camshaft seals gaps as shown.

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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the camshaft caps, oil tube and the bolts.

Torque: Stage 1: 8 Nm Stage 2: 45deg.

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Loosen the camshaft cap bolts.

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Tighten the camshaft cap bolts.
Torque: Stage 1: 8 Nm Stage 2: 45deg.

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NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Adjustment

(303-01A Engine - 3.5L EcoBoost (235kW/320PS), General Procedures).Use the General Equipment: Feeler Gauge

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Apply 8mm dots of sealant to the camshaft bearing cap as shown.
Material: Flange Sealant (WSS-M2G348-A11)

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Install the camshaft bearing cap and bolts.
Torque: Stage 1: 10 Nm Stage 2: 45deg.

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Remove the bolts and the oil tube.

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Rotate the RH camshafts to TDC.

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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

Install Special Service Tool: 303-1248 Camshaft holding tools.

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NOTE: The VCT oil control solenoids are removed for clarity.

Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Align the colored links with the timing marks and assemble the RHVCT units.

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NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

Position the RHVCT units and secondary timing chain onto the camshafts by aligning the holes in the VCT units with the dowel pins in the camshafts.

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Install the new RHVCT unit bolts.
Torque: Stage 1: 40 Nm Stage 2: Loosen: : 1 turn(s) Stage 3: 25 Nm Stage 4: 180deg.

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NOTE: Make sure the secondary timing chain is centered on the timing chain tensioner guides.

NOTE: The VCT oil control solenoids are removed for clarity.

Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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NOTE: Coat the camshafts with clean engine oil prior to installation.

Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral position as shown. Refer to: Specifications .

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NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

Position the LH camshaft seals gaps as shown.

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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the camshaft caps, oil tube and the bolts.

Torque: Stage 1: 8 Nm Stage 2: 45deg.

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Loosen the camshaft cap bolts.

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Tighten the camshaft cap bolts.
Torque: Stage 1: 8 Nm Stage 2: 45deg.

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NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Adjustment

(303-01A Engine - 3.5L EcoBoost (235kW/320PS), General Procedures).Use the General Equipment: Feeler Gauge

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Remove bolts and the oil tube.

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Rotate the LH camshafts to TDC.

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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

Install Special Service Tool: 303-1248 Camshaft holding tools.

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NOTE: The VCT oil control solenoids are removed for clarity.

Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Align the colored links with the timing marks and assemble the LHVCT units.

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NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

Position the LHVCT units and secondary timing chain onto the camshafts by aligning the holes in the VCT units with the dowel pins in the camshafts.

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Install the new LHVCT unit bolts.
Torque: Stage 1: 40 Nm Stage 2: Loosen: : 1 turn(s) Stage 3: 25 Nm Stage 4: 180deg.

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NOTE: Make sure the secondary timing chain is centered on the timing chain tensioner guides.

NOTE: The VCT oil control solenoids are removed for clarity.

Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Install the LH upper primary timing chain guide and the bolt.
Torque: 10 Nm

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Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).

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Install the crankshaft sprocket.

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NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.

Install the timing chain with the colored links aligned with the timing marks on the VCT units and the crankshaft sprocket.

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Install the lower LH timing chain guide and the bolts.
Torque: 10 Nm

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Install the timing chain tensioner arm.

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1. Position the tensioner in a soft-jawed vise.
2. Using pliers, squeeze the ends of the ratchet wire clip together.
3. Using the soft-jawed vise, compress the plunger to the reset position.
4. Install a locking pin in the 2 holes of the tensioner body to hold the plunger in place.
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NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.
1. Install the timing chain tensioner and the bolts.
  Torque: 10 Nm
2. Remove the lockpin.
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Remove Special Service Tool: 303-1248 Camshaft holding tools.

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Install the RH oil tube and the bolts.
Torque: Stage 1: 8 Nm Stage 2: 60deg.

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Remove Special Service Tool: 303-1248 Camshaft holding tools.

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Install the LH oil tube and the bolts.
Torque: Stage 1: 8 Nm Stage 2: 60deg.

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- Remove the original crankshaft pulley bolt and washer.
- Discard the crankshaft pulley bolt.
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- As a post-check, verify correct alignment of all timing marks.
- There are 48 links in between the RH intake VCT unit colored link (1) and the LH intake VCT unit colored link (2).
- There are 35 links in between LH intake VCT unit colored link (2) and the 2 crankshaft sprocket links (3).
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NOTE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

Install the VCT oil control solenoids and the bolts.

Torque: Stage 1: 8 Nm Stage 2: 20deg.

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Using the special tools, install the front cover to coolant pipe seal.Use Special Service Tool: 205-150 (T80T-4000-S) Installer, Spindle Bearing., 205-153 (T80T-4000-W) Handle.

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Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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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 and 6 bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. Failure to follow this procedure can cause future oil leakage.
- Apply a 5 mm (0.20 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.
  Material: RTV silicone sealant (WSE-M4G323-A6)
- Apply a 9 mm (0.35 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in places as indicated.
  Material: RTV silicone sealant (WSE-M4G323-A6)
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NOTE: It will be necessary to obtain 2 W503297 (10 mm Hex) M8 x 1.25 x 35 bolts and washers to replace the power steering pump bracket bolts during the front cover tightening process.

NOTE: Make sure the locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and the bolts.

Torque: 3 Nm

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Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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NOTE: If equipped with dual generators, after the tightening sequence is completed, the W503297 (10 mm HEX) M8 X 1.25 X 35 bolt and washer will be removed to accommodate installation of the accessory bracket.

Install the remaining engine front cover bolts.

Torque: Stage 1: Tighten bolts 1 thru 21 to : 10 Nm Stage 2: Tighten bolts 1 thru 20 to : 24 Nm Stage 3: Tighten bolt 21 to : 20 Nm Stage 4: Tighten bolt 21 an additional : 90deg. Stage 5: Tighten bolt 22 to : 10 Nm Stage 6: Tighten bolt 22 an additional : 45deg.

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This step only necessary if equipped with dual alternators.Remove the bolts.

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Install the coolant pump and the bolts.

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Remove the bolts and the coolant pump.
Torque: Stage 1: 10 Nm Stage 2: 45deg.

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NOTE: Apply clean engine oil to the CMP sensor O-ring seals.

Install the CMP sensors and the bolts. Refer to: Specifications .

Torque: 10 Nm

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NOTE: Installation of new seals is only required if damaged seals were removed.

NOTE: RH shown, LH similar.

If removed, using the special tools, install the spark plug tube seals.Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer., 205-153 (T80T-4000-W) Handle.

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NOTE: Installation of new seals is only required if damaged seals were removed.

NOTE: RH shown, LH similar.

If removed, using the special tools, install the VCT oil control solenoid seals.Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone., 205-153 (T80T-4000-W) Handle.

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Install a new RH valve cover gasket.

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NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to- RH cylinder head joints.

Material: metal cleaner

Material: gasket remover

Material: RTV silicone sealant (WSE-M4G323-A6)

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Install the valve cover and tighten the bolts.
Torque: 10 Nm

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Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.

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Install a new LH valve cover gasket.

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NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to- LH cylinder head joints.

Material: metal cleaner

Material: gasket remover

Material: RTV silicone sealant (WSE-M4G323-A6)

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Install the LH valve cover and tighten the bolts.
Torque: 10 Nm

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Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.

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Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before installing.
Material: grease - silicone (ESA-M1C200-A) (ESE-M1C171-A)

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- NOTE: Apply clean engine oil to the CMP sensor O-ring seals.
  
  Install the CMP sensors and the bolts. Refer to: Specifications .
  
  Torque: 10 Nm
- Install all of the coil-on-plugs and the bolts.
  Torque: 7 Nm
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Install the cabin pump and nuts.
Torque: 5 Nm

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- Install the engine wiring harness attach all of the wiring harness retainers.
- Connect the coil-on-plug electrical connectors.
- Connect the CMP sensor electrical connectors.
- Connect the VCT sensor electrical connectors.
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- Attach the wiring harness retainers.
- Connect the coil-on-plug electrical connectors.
- Connect the VCT sensor electrical connectors.
- Install the oil level indicator.
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Connect the electrical connector and attach the pin-type retainer.

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- Install the CKP sensor and bolt.
  Torque: 10 Nm
- Connect the CKP sensor electrical connector.
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- Attach the wiring harness grommet to the cylinder block.
- Install the stud bolt.
  Torque: 10 Nm
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Remove the nut, bolt and the heat shield.
Torque: 10 Nm

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- Install the ground wire and stud bolt.
  Torque: Stage 1: 10 Nm Stage 2: 20deg.
- Attach the wiring harness retainer and if equipped, install the nut.
  Torque: 10 Nm
- Connect the CMP sensor electrical connectors.
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- Connect the RH and LH fuel charge harness electrical connectors.
- Connect the fuel pressure sensor electrical connector.
- Connect the KS electrical connector.
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- Install the ground wire and stud bolt.
  Torque: 10 Nm
- Connect the CHT sensor electrical connector and wiring harness retainer.
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NOTE: Make sure that the mating faces are clean and free of foreign material.

Clean the surface and apply an 8mm bead of sealer.

Material: Metal Cleaner

Material: RTV Silicone Sealant (WSE-M4G323-A6)

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NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.

Install the vacuum pump and the bolts.

Torque: Stage 1: 10 Nm Stage 2: 45deg.

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Install the heat shield, bolt and nut.
Torque: 10 Nm

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Install the RH block coolant drain plug.
Torque: Stage 1: 16 Nm Stage 2: 180deg.

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Install the LH block coolant drain plug.
Torque: 40 Nm

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Install the oil filter adapter and the bolts finger-tight.

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Tighten the bolt.
Torque: 42 Nm

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Tighten the bolts.
Torque: Stage 1: 10 Nm Stage 2: 45deg.

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Install the coolant hose bracket and bolt.
Torque: 5 Nm

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NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

Install the new oil cooler and the bolt.

Torque: 58 Nm

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1. Attach the wiring harness retainer.
2. Connect the CHT sensor electrical connector.
3. Slide the insulator onto the CHT sensor electrical connector.
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Install the generator stud bolt.
Torque: 8 Nm

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Install the generator, nut and bolt.
Torque: 47 Nm

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Install the coolant tube fitting.
Torque: 50 Nm

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Lubricate the turbocharger fitting and oil filter assembly O-ring with clean engine oil. Refer to: Specifications .

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Install the turbocharger fitting and oil filter assembly.
Torque: 48 Nm

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NOTE: Make sure that the mating faces are clean and free of foreign material.
Lubricate the turbocharger fitting and oil filter assembly O-ring with clean engine oil. Refer to: Specifications .

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Install the turbocharger fitting and oil filter assembly.
Torque: 48 Nm

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Install the new turbocharger oil manifold assembly O-ring seal and gasket. Lubricate the new turbocharger oil manifold assembly O-ring seal with clean engine oil. Refer to: Specifications .

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NOTE: Lubricate the cylinder block bore with clean engine oil.

Install the turbocharger oil tube assembly, then install and tighten the turbocharger oil tube assembly lower bolt in the following 2 stages. Refer to: Specifications .

Torque: Stage 1: 8 Nm Stage 2: 30deg.

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NOTE: Apply high temperature nickel anti-seize lubricant to the turbocharger exhaust stud bolt threads prior to installation.

If removed install and tighten the turbocharger exhaust flange stud bolts.

Material: Anti-Seize Lubricant

Torque: 25 Nm

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Install the new turbocharger gasket.

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Inspect the turbocharger coolant tube turbocharger fitting and replace as needed.
Torque: 18 Nm

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Place the turbocharger in the vehicle. Connect the turbocharger coolant tube to the turbocharger fitting.

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Inspect the turbocharger coolant supply tube-to-engine block fitting and replace as needed.
Torque: 50 Nm

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NOTE: Install the turbocharger and install the new turbocharger fasteners finger tight at this stage.

NOTE: Install the turbocharger coolant supply tube to the engine block fitting while installing the turbocharger.
1. Tighten the new turbocharger fasteners.
  Torque: 32 Nm
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Install the new upper turbocharger oil tube assembly gasket.

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NOTE: Install the turbocharger oil tube assembly upper bolts finger tight at the turbocharger.
1. Tighten the outer turbocharger oil tube manifold bolt.
  Torque: 5 Nm
2. Tighten the inner turbocharger oil tube bolt in the following 2 stages.
  Torque: Stage 1: 10 Nm Stage 2: 30deg.
3. Tighten the outer turbocharger oil tube bolt in the following 2 stages.
  Torque: Stage 1: 10 Nm Stage 2: 30deg.
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Install the turbocharger coolant supply tube and the turbocharger oil feed tube bolt and tighten the bolt.
Torque: Stage 1: 8 Nm Stage 2: 30deg.

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Connect the electrical connector to the oil pressure switch and install the cover.

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Connect the turbocharger coolant return tube at the turbocharger.

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NOTE: Make sure that the mating faces are clean and free of foreign material.
Lubricate the O-ring with clean engine oil. Refer to: Specifications .

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Install and tighten the turbocharger fitting and oil filter assembly.
Torque: 32 Nm

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Install the new O-ring seal, then lubricate with clean engine oil. Refer to: Specifications .

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- Lubricate the cylinder block bore with clean engine oil. Refer to: Specifications .
1. Install the turbocharger oil tube assembly, then install and tighten the lower bolt in the following 2 stages.
  Torque: Stage 1: 8 Nm Stage 2: 30deg.
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Install the new the turbocharger exhaust flange gasket.

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- Apply high temperature nickel anti-seize lubricant to the turbocharger exhaust flange studbolt threads prior to installation.
1. Install the turbocharger exhaust flange, then install and tighten the new studbolts.
  Material: Anti-Seize Lubricant
  
  Torque: 40 Nm
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Install the new turbocharger gasket.

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Inspect the fitting and replace as needed.
Torque: 18 Nm

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Connect the turbocharger coolant tube.

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Inspect the fitting and replace as needed.
Torque: 50 Nm

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Install the new turbocharger mounting bolts, install the turbocharger coolant supply tube to the block fitting while installing the turbocharger.
Torque: 32 Nm

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Install the new upper turbocharger oil tube assembly gasket.

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- Install the turbocharger oil tube assembly upper bolts finger tight.
1. Tighten the outer bolt.
  Torque: 5 Nm
2. Tighten the inner bolt in the following 2 stages.
  Torque: Stage 1: 10 Nm Stage 2: 30deg.
3. Tighten the outer bolt in the following 2 stages.
  Torque: Stage 1: 10 Nm Stage 2: 30deg.
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Install and tighten the bolt for the turbocharger tubes.
Torque: Stage 1: 8 Nm Stage 2: 30deg.

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Inspect the turbocharger coolant return tube fitting and replace as needed.
Torque: 18 Nm

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Install and connect the turbocharger coolant return tube.

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Install the coolant tube fitting.
Torque: 50 Nm

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Lubricate the turbocharger fitting and oil filter assembly O-ring with clean engine oil. Refer to: Specifications .

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Install the turbocharger fitting and oil filter assembly.
Torque: 32 Nm

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NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.

NOTE: The cam 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 fuel injection pump cam lobe is at BDC.

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Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the camshaft lobe and the high-pressure fuel pump roller tappet. Install the high-pressure fuel pump roller tappet. Refer to: Specifications .

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NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.

Install a new O-ring seal. Refer to: Specifications .

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- Install the high-pressure fuel pump.
- Install new bolts and alternately tighten each bolt one revolution until pump is seated.
  Torque: Stage 1: 20 Nm Stage 2: 45deg.
- Connect the high-pressure fuel pump electrical connector.
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NOTE: Make sure that a new high pressure fuel tube, a new high pressure fuel tube bracket nut and a new high pressure fuel tube bracket bolt are installed.

NOTE: Install the new high pressure fuel tube, the high pressure fuel tube flare nuts, the new high pressure fuel tube bracket nut, the new bracket bolt and tighten finger tight at this stage. Tighten in the sequence shown.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas.
1. Tighten the high pressure fuel tube-to-RH fuel rail tube flare nut.
  Torque: Stage 1: 10 Nm Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30deg.
2. Tighten the high pressure fuel tube-to-LH fuel rail tube flare nut.
  Torque: Stage 1: 10 Nm Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30deg.
3. Tighten the high pressure fuel tube-to-high-pressure fuel pump flare nut.
  Torque: Stage 1: 10 Nm Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30deg.
4. Tighten the high pressure fuel tube bracket bolt.
  Torque: Stage 1: 10 Nm Stage 2: 45deg.
5. Tighten the high pressure fuel tube bracket nut.
  Torque: 8 Nm
Fig 2: High Pressure Fuel Tube Tightening Sequence
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Install new gaskets.

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Install the coolant outlet and the bolts.
Torque: Stage 1: 10 Nm Stage 2: 45deg.

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- Install new O-ring seals.
- Install the coolant pipe.
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If necessary, install a new O-ring seal.

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Install the thermostat housing and the bolts.
Torque: Stage 1: 8 Nm Stage 2: 45deg.

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1. Install the coolant pump pulley and the bolts.
  Torque: 24 Nm
2. Install the accessory drive belt tensioner and the bolts.
  Torque: 25 Nm
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Lubricate the crankshaft front seal bore with clean engine oil. Refer to: Specifications .

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Using the special tools, install the crankshaft front seal.Use Special Service Tool: 303-102 Installer, Crankshaft Pulley., 303-1251 Installer, Front Seal.

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Verify the crankshaft front seal is seated and lubricate the crankshaft pulley with clean engine oil. Refer to: Specifications .

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Using the special tools, install the crankshaft pulley.Use Special Service Tool: 303-102 Installer, Crankshaft Pulley., 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal.

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Install the new crankshaft bolt and the washer.Use the General Equipment: Strap Wrench
Torque: Stage 1: 120 Nm Stage 2: Loosen: : 1 turn(s) Stage 3: 50 Nm Stage 4: 90deg.

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Install the A/C compressor and the bolts.
Torque: 25 Nm

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This step is only necessary if the intake manifold gaskets were discarded on inspection.Install new intake manifold gaskets.

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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.

Install the intake manifold and the bolts.

Torque: Stage 1: 10 Nm Stage 2: 45deg.

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Connect the MAPT sensor electrical connector and wiring harness retainer.

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Connect the throttle body electrical connector and wiring harness retainer.

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- Install the vacuum solenoid assembly, the retaining plate and the pin-type retainer.
- Attach the vacuum hose retainers to the valve covers.
- Connect the electrical connector to the vacuum solenoid.
- Connect the vacuum hoses to the turbochargers.
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Install the PCV tube.

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- Install the vapor tube assembly and stud bolt.
  Torque: 10 Nm
- Connect the vapor tube coupling to the intake manifold. Refer to: QUICK RELEASE COUPLING
- Connect the EVAP purge valve electrical connector.
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- Install the vacuum tube assembly and attach the retainers.
- Connect the vacuum tube coupling to the vacuum pump. Refer to: QUICK RELEASE COUPLING
- Connect the vacuum hose to the intake manifold.Use the General Equipment: Hose Clamp Remover/Installer
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- Follow the directions to install coupling type 3. Disconnect the quick release coupling and remove the PCV tube. Refer to: QUICK RELEASE COUPLING
- Disconnect the crankcase pressure sensor electrical connector.
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Install the RH engine mount bracket and the bolts.
Torque: 63 Nm

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Install the LH engine mount bracket and the bolts.
Torque: 63 Nm

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Install the coolant hose.

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Install commercially available quick links and floor crane.Use the General Equipment: Floor Crane

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

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

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NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position

Install the flexplate and the bolts.

Torque: 80 Nm

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