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Section 152 (Engine - 3.5L DURATEC (202KW/275PS)): Assembly: Engine

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Special Tool(s) / General Equipment 

GFD838168Courtesy of FORD MOTOR COMPANY
 100-002 (TOOL-4201-C)Holding Fixture with Dial Indicator Gauge
GFD837849Courtesy of FORD MOTOR COMPANY
 205-142 (T80T-4000-J)Installer, Differential Bearing Cone
GFD837693Courtesy of FORD MOTOR COMPANY
 205-149 (T80T-4000-R)Installer, Spindle Bearing
GFD836857Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W)Handle
GFD73699Courtesy of FORD MOTOR COMPANY
 303-102Installer, Crankshaft Pulley
GFD838423Courtesy of FORD MOTOR COMPANY
 303-103 (T74P-6375-A)Holding Tool, Flywheel
GFD74351Courtesy of FORD MOTOR COMPANY
 303-1245Engine Lift Eye
GFD837850Courtesy of FORD MOTOR COMPANY
 303-1247VCT Spark Plug Tube Seal Remover and Installer
GFD837602Courtesy of FORD MOTOR COMPANY
 303-1248Camshaft holding tools
GFD838169Courtesy of FORD MOTOR COMPANY
 303-1250Seal Installer, Rear Main
GFD73700Courtesy of FORD MOTOR COMPANY
 303-1251Installer, Front Seal
GFD73672Courtesy of FORD MOTOR COMPANY
 303-1530Tool, Chain Tensioner Hold Down
GFD838391Courtesy of FORD MOTOR COMPANY
 303-1663Installer, VDOP Seal
GFD837629Courtesy of FORD MOTOR COMPANY
 303-335 (T88T-6701-A)Installer, Front Cover Oil Seal
GFD73760Courtesy of FORD MOTOR COMPANY
 307-399Alignment Pins, Transmission Fluid Pump
Feeler Gauge
Floor Crane
Mounting Stand
Round-Ended Steel Rule
Piston Ring Compressor

Materials 

Name Specification
RTV Silicone Sealant WSE-M4G323-A6
Anti-Seize Lubricant -
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 
  1. Using a hex bit, install the piston oil cool valves.

    Torque: 4 Nm

    GFD838106Courtesy of FORD MOTOR COMPANY
  2. 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.

    GFD838170Courtesy of FORD MOTOR COMPANY
  3. 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.

    GFD838171Courtesy of FORD MOTOR COMPANY
  4. NOTE: This chart is for selecting main bearings 1 and 4 only.
    GFD838172Courtesy of FORD MOTOR COMPANY
  5. 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.

    GFD838173Courtesy of FORD MOTOR COMPANY
  6. NOTE: This chart is for selecting main bearings 2 and 3 only.
    GFD838174Courtesy 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 rod caps and bolts.

    Torque: Stage 1: 23 Nm Stage 2: 43 Nm Stage 3: 105deg.

    GFD838175Courtesy of FORD MOTOR COMPANY
  8. Measure the connecting rod large end bore in 2 directions.
    GFD838176Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the rod cap.

    • Discard the bolts.

    GFD838177Courtesy of FORD MOTOR COMPANY
  10. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
    GFD838178Courtesy of FORD MOTOR COMPANY
  11. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    GFD838179Courtesy 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.

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

    GFD838180Courtesy of FORD MOTOR COMPANY
  13. 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.

    GFD838103Courtesy of FORD MOTOR COMPANY
  14. 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.

    GFD838181Courtesy of FORD MOTOR COMPANY
  15. 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.

    GFD838182Courtesy of FORD MOTOR COMPANY
  16. 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.
    GFD838183Courtesy of FORD MOTOR COMPANY
  17. 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.
    GFD838184Courtesy of FORD MOTOR COMPANY
  18. 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.

    GFD838101Courtesy of FORD MOTOR COMPANY
  19. 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.
    GFD838185Courtesy of FORD MOTOR COMPANY
  20. 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: Stage 1: 27 Nm Stage 2: 180deg.

    GFD838186Courtesy of FORD MOTOR COMPANY
  21. Install the new main bearing cap side bolts.

    Torque: Stage 1: 45 Nm Stage 2: 90deg.

    GFD838187Courtesy of FORD MOTOR COMPANY
    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.
    GFD838188Courtesy of FORD MOTOR COMPANY
  23. 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.

    GFD838189Courtesy of FORD MOTOR COMPANY
  24. 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.

    GFD838167Courtesy of FORD MOTOR COMPANY
  25. 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.Use the General Equipment: Piston Ring Compressor

    • Repeat until all 6 piston assemblies are installed.

    GFD838190Courtesy of FORD MOTOR COMPANY
  26. 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: 105deg.

    GFD838097Courtesy of FORD MOTOR COMPANY
  27. Install the main bearing cap support brace and the new bolts.

    Torque: Stage 1: 27 Nm Stage 2: 225deg.

    GFD838737Courtesy of FORD MOTOR COMPANY
  28. 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 10 minutes of sealant application.

    Apply a 4.5 mm (0.177 in) bead of Motorcraft® High Performance Engine RTV Silicone on the break edge between the mating surface and the step chamfer.

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

    GFD838350Courtesy of FORD MOTOR COMPANY
  29. Lubricate the crankshaft with clean engine oil.
    GFD838193Courtesy of FORD MOTOR COMPANY
    1. Lubricate the special tool with clean engine oil and install.Install Special Service Tool: 303-1250 Seal Installer, Rear Main.
    2. NOTE: Inspect and ensure that the crankshaft rear seal lip is not rolled before proceeding to step 31.

      Install the crankshaft rear seal.

    3. Remove the special tool.Remove Special Service Tool: 303-1250 Seal Installer, Rear Main.
    GFD838194Courtesy of FORD MOTOR COMPANY
  31. NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 10 minutes of sealant application.

    Install the crankshaft rear seal bolts and tighten in sequence shown.

    Torque: 10 Nm

    GFD838195Courtesy of FORD MOTOR COMPANY
  32. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
  33. Install the oil pump and the bolts.

    Torque: 10 Nm

    GFD838699Courtesy of FORD MOTOR COMPANY
  34. Install a new oil pump screen and pickup tube O-ring seal.
    GFD838494Courtesy of FORD MOTOR COMPANY
  35. Install the oil pump screen and the pickup tube and the bolts.

    Torque: 10 Nm

    GFD838698Courtesy of FORD MOTOR COMPANY
  36. 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 (0.2 in) bead of Motorcraft® High Performance Engine RTV Silicone on the chamfer, as shown.

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

    GFD838495Courtesy of FORD MOTOR COMPANY
  37. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The oil pan and the specified bolts must be installed and the oil pan aligned to the cylinder block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

    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.

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

    GFD838496Courtesy of FORD MOTOR COMPANY
  38. Install the oil pan and bolts.

    Torque: Stage 1: 3 Nm Stage 2: Loosen: 180deg.

    GFD838196Courtesy of FORD MOTOR COMPANY
  39. 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
    GFD838197Courtesy of FORD MOTOR COMPANY
  40. Tighten the bolts finger tight.

    Torque: 3 Nm

    GFD838198Courtesy of FORD MOTOR COMPANY
  41. NOTE: The oil pan bolts must be installed and tightened within 10 minutes of the initial sealant application.

    • Install the remaining oil pan bolts. Tighten in the sequence shown.

      Torque: Stage 1: Tighten bolts 1-9 and 11-14 to: 20 Nm Stage 2: Tighten bolts 1-9 and 11-14 an additional: 45deg. Stage 3: Tighten bolt 10 to: 20 Nm Stage 4: Tighten bolt 10 an additional: 90deg. Stage 5: Tighten bolts 15 and 16 to: 10 Nm Stage 6: Tighten bolts 15 and 16 an additional: 45deg.

    • Rotate the engine so the oil pan is facing downwards.

    GFD838199Courtesy of FORD MOTOR COMPANY
  42. Install the channel cover plate and the bolts.

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

    GFD838200Courtesy of FORD MOTOR COMPANY
  43. Install the KS and the bolts.

    Torque: 20 Nm

    GFD838695Courtesy of FORD MOTOR COMPANY
  44. Inspect for any debri before installing the LH water jacket.
    GFD838209Courtesy of FORD MOTOR COMPANY
  45. Install the LH water jacket flush with the bottom of the block.
    GFD838210Courtesy of FORD MOTOR COMPANY
  46. Install the LH cylinder head gasket.
    GFD837669Courtesy of FORD MOTOR COMPANY
  47. NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

    Install the cylinder head and the new bolts.

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

    GFD838738Courtesy of FORD MOTOR COMPANY
  48. Install the M6 bolt.

    Torque: 10 Nm

    GFD837671Courtesy of FORD MOTOR COMPANY
  49. Inspect for any debri before installing the RH water jacket.
    GFD838201Courtesy of FORD MOTOR COMPANY
  50. Install the RH water jacket flush with the bottom of the block.
    GFD838202Courtesy of FORD MOTOR COMPANY
  51. Install the RH cylinder head gasket.
    GFD837689Courtesy of FORD MOTOR COMPANY
  52. NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

    Install the cylinder head and the new bolts.

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

    GFD838739Courtesy of FORD MOTOR COMPANY
  53. Install the M6 bolt.

    Torque: 10 Nm

    GFD837691Courtesy of FORD MOTOR COMPANY
  54. NOTE: Coat the valve tappets with clean engine oil prior to installation.
    NOTE: The valve tappets must be installed in their original positions.
    NOTE: RH shown, LH similar.

    Install the valve tappets.

    GFD838534Courtesy of FORD MOTOR COMPANY
  55. Install the LH upper primary timing chain guide and the bolt.

    Torque: 10 Nm

    GFD838688Courtesy of FORD MOTOR COMPANY
  56. Install the RH primary timing chain guide and the bolts.

    Torque: 10 Nm

    GFD838687Courtesy of FORD MOTOR COMPANY
  57. Install the original crankshaft bolt and washer.
    GFD838740Courtesy of FORD MOTOR COMPANY
  58. 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.

    Using the crankshaft bolt, position the crankshaft dowel pin in the 9 o'clock position.

    GFD838741Courtesy of FORD MOTOR COMPANY
  59. 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.

    GFD838742Courtesy of FORD MOTOR COMPANY
  60. 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.

    GFD837612Courtesy of FORD MOTOR COMPANY
  61. 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: Tighten bolts 1, 2, 4, 5, 6 and 7 to: 8 Nm Stage 2: Tighten bolts 1, 2, 4, 5, 6 and 7 an additional: 45deg. Stage 3: Tighten bolts 8, 9, 10 and 11 to: 8 Nm Stage 4: Tighten bolts 12, 13, 14 and 15 to: 8 Nm Stage 5: Tighten bolts 12, 13, 14 and 15 an additional: 45deg.

    • The camshaft torque sequence (bolt 3) will be finished after the timing chain is installed.

    GFD838743Courtesy of FORD MOTOR COMPANY
  62. Loosen the camshaft cap bolts.
    GFD838744Courtesy of FORD MOTOR COMPANY
  63. Tighten the camshaft cap bolts.

    Torque: Stage 1: 8 Nm Stage 2: 60deg.

    GFD838745Courtesy of FORD MOTOR COMPANY
  64. 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 

    (303-01B Engine - 3.5L Duratec (202kW/275PS), General Procedures).Use the General Equipment: Feeler Gauge

    GFD837616Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the RH oil tube.

    • Loosen the 2 bolts.

    GFD838326Courtesy of FORD MOTOR COMPANY
  66. Rotate the RH camshafts to TDC.
    GFD838746Courtesy of FORD MOTOR COMPANY
  67. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

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

    GFD837607Courtesy of FORD MOTOR COMPANY
  68. NOTE: The VCT oil control solenoids are removed for clarity.

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

    GFD838747Courtesy of FORD MOTOR COMPANY
  69. Align the colored links with the timing marks and assemble the RH VCT units.
    GFD838553Courtesy of FORD MOTOR COMPANY
  70. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

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

    GFD838684Courtesy of FORD MOTOR COMPANY
  71. Install the new RH VCT unit bolts.

    Torque: Stage 1: 40 Nm Stage 2: Loosen: 1 turn(s) Stage 3: 25 Nm Stage 4: 180deg.

    GFD838748Courtesy of FORD MOTOR COMPANY
  72. 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.

    GFD838682Courtesy of FORD MOTOR COMPANY
  73. 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.

    GFD838749Courtesy of FORD MOTOR COMPANY
  74. 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.

    GFD837621Courtesy of FORD MOTOR COMPANY
  75. 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: Tighten bolts 1, 2, 4, 5, 6 and 7 to: 8 Nm Stage 2: Tighten bolts 1, 2, 4, 5, 6 and 7 an additional: 45deg. Stage 3: Tighten bolts 8, 9, 10 and 11 to: 8 Nm Stage 4: Tighten bolts 12, 13, 14 and 15 to: 8 Nm Stage 5: Tighten bolts 12, 13, 14 and 15 an additional: 45deg.

    • The camshaft torque sequence (bolt 3) will be finished after the timing chain is installed.

    GFD838750Courtesy of FORD MOTOR COMPANY
  76. Loosen the camshaft cap bolts.
    GFD838751Courtesy of FORD MOTOR COMPANY
  77. Tighten the camshaft cap bolts in sequence shown.

    Torque: Stage 1: 8 Nm Stage 2: 60deg.

    GFD838752Courtesy of FORD MOTOR COMPANY
  78. 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 

    (303-01B Engine - 3.5L Duratec (202kW/275PS), General Procedures).Use the General Equipment: Feeler Gauge

    GFD837625Courtesy of FORD MOTOR COMPANY
    • Remove bolts and the LH oil tube.

    • Loosen the 2 bolts.

    GFD838334Courtesy of FORD MOTOR COMPANY
  80. Rotate the LH camshafts to TDC.
    GFD838753Courtesy of FORD MOTOR COMPANY
  81. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

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

    GFD837604Courtesy of FORD MOTOR COMPANY
  82. NOTE: The VCT oil control solenoids are removed for clarity.

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

    GFD838754Courtesy of FORD MOTOR COMPANY
  83. Align the colored links with the timing marks and assemble the LH VCT units.
    GFD838563Courtesy of FORD MOTOR COMPANY
  84. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

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

    GFD838679Courtesy of FORD MOTOR COMPANY
  85. Install the new LH VCT unit bolts.

    Torque: Stage 1: 40 Nm Stage 2: Loosen: 1 turn(s) Stage 3: 25 Nm Stage 4: 180deg.

    GFD838755Courtesy of FORD MOTOR COMPANY
  86. 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.

    GFD838677Courtesy of FORD MOTOR COMPANY
  87. Using the crankshaft bolt, rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
    GFD838756Courtesy of FORD MOTOR COMPANY
  88. Remove the crankshaft pulley bolt.
    GFD838757Courtesy of FORD MOTOR COMPANY
  89. Install the crankshaft sprocket.
    GFD838676Courtesy of FORD MOTOR COMPANY
  90. 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.

    GFD838758Courtesy of FORD MOTOR COMPANY
  91. Install the lower LH timing chain guide and the bolts.

    Torque: 10 Nm

    GFD838759Courtesy of FORD MOTOR COMPANY
  92. Install the timing chain tensioner arm.
    GFD838760Courtesy of FORD MOTOR COMPANY
    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.
    GFD837844Courtesy of FORD MOTOR COMPANY
  94. 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.

    GFD837845Courtesy of FORD MOTOR COMPANY
    • 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).

    GFD838761Courtesy of FORD MOTOR COMPANY
  96. 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.

    GFD838673Courtesy of FORD MOTOR COMPANY
  97. Remove Special Service Tool: 303-1248 Camshaft holding tools.
    GFD837805Courtesy of FORD MOTOR COMPANY
  98. Install the RH oil tube and the bolts finger tight.

    Torque: Stage 1: Tighten bolts 1, 2 and 3 to: 8 Nm Stage 2: Tighten bolts 1, 2 and 3 an additional: 60deg. Stage 3: Tighten bolts 4 and 5 to: 8 Nm Stage 4: Tighten bolts 4 and 5 an additional: 45deg.

    GFD838762Courtesy of FORD MOTOR COMPANY
  99. Remove Special Service Tool: 303-1248 Camshaft holding tools.
    GFD837803Courtesy of FORD MOTOR COMPANY
  100. Install the LH oil tube and the bolts finger tight.

    Torque: Stage 1: Tighten bolts 1, 2 and 3 to: 8 Nm Stage 2: Tighten bolts 1, 2 and 3 an additional: 60deg. Stage 3: Tighten bolts 4 and 5 to: 8 Nm Stage 4: Tighten bolts 4 and 5 an additional: 45deg.

    GFD838763Courtesy of FORD MOTOR COMPANY
  101. Using the special tools, install the front cover to coolant pipe seal.Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing., 205-153 (T80T-4000-W) Handle.
    GFD838402Courtesy of FORD MOTOR COMPANY
  102. Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
    GFD838764Courtesy of FORD MOTOR COMPANY
  103. 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 the 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 10 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 3 mm (0.12 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover inner bolt bosses.

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

    • Apply a 5 mm (0.19 in) bead of Motorcraft® High Performance Engine RTV Silicone on the chamfer, as shown.

      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)

    GFD838404Courtesy of FORD MOTOR COMPANY
  104. 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

    GFD838765Courtesy of FORD MOTOR COMPANY
  105. Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
    GFD838766Courtesy of FORD MOTOR COMPANY
  106. NOTE: The engine front cover bolts must be installed and tightened within 10 minutes of the initial sealant application.

    Install the remaining engine front cover bolts.

    Torque: Stage 1: Tighten bolts 1 through 21 to: 10 Nm Stage 2: Tighten bolts 1 through 20 and 23 to: 20 Nm Stage 3: Tighten bolts 1 through 20 and 23 an additional: 45deg. Stage 4: Tighten bolt 21 to: 20 Nm Stage 5: Tighten bolt 21 an additional: 90deg. Stage 6: Tighten bolt 22 to: 10 Nm Stage 7: Tighten bolt 22 an additional: 45deg.

    GFD838767Courtesy of FORD MOTOR COMPANY
  107. Using the special tool and a hammer, install the oil pump electrical connector seal.Use Special Service Tool: 303-1663 Installer, VDOP Seal.
    GFD838409Courtesy of FORD MOTOR COMPANY
  108. Make sure the oil pump electrical connector seal is below the top of the oil pump electrical connector or the oil pump electrical connector seal may leak oil.
    GFD838410Courtesy of FORD MOTOR COMPANY
  109. Install a new coolant pump gasket and O-ring seal.
    GFD838768Courtesy of FORD MOTOR COMPANY
  110. Install the coolant pump and the bolts.

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

    GFD838769Courtesy of FORD MOTOR COMPANY
  111. NOTE: Make sure that a new fuel rail to fuel rail high-pressure fuel tube is installed.

    • Install the fuel rail to fuel rail high-pressure fuel tube and finger tight the flare nuts.

    • Tighten the flare nuts in the following 3 stages.

      Torque: Stage 1: 7 Nm Stage 2: 10 Nm Stage 3: If the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 75 Nm (55 lb-ft), the high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.: 30deg.

    GFD838770Courtesy of FORD MOTOR COMPANY
  112. 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 lower intake manifold and the bolts.

    Torque: 10 Nm

    GFD838771Courtesy of FORD MOTOR COMPANY
  113. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not interchangeable.
    NOTE: Make sure that new fuel injector O-ring seals are installed.

    • Install the new fuel injector O-ring seals onto the fuel injectors.

    • Lubricate the new fuel injector O-ring seals with clean engine oil.

    GFD838772Courtesy of FORD MOTOR COMPANY
    1. Install the fuel injectors into the fuel rail.
    2. Install the fuel injectors retaining clips.
    GFD838773Courtesy of FORD MOTOR COMPANY
  115. Install the port injection fuel rail and the bolts.

    Torque: 10 Nm

    GFD838660Courtesy of FORD MOTOR COMPANY
  116. NOTE: Apply clean engine oil to the CMP sensor O-ring seals.

    Install the CMP sensors and the bolts.

    Torque: 10 Nm

    GFD838659Courtesy of FORD MOTOR COMPANY
  117. Install the heat shield and the stud bolts.

    Torque: 10 Nm

    GFD838658Courtesy of FORD MOTOR COMPANY
    1. Install the LH block coolant drain plug.

      Torque: 40 Nm

    2. If equipped, install the block heater.

      Torque: 40 Nm

    GFD838657Courtesy of FORD MOTOR COMPANY
  119. Install the RH block coolant drain plug.

    Torque: Stage 1: 16 Nm Stage 2: 180deg.

    GFD838656Courtesy of FORD MOTOR COMPANY
    • Install the exhaust manifold studs.

      Torque: 12 Nm

    • Install the exhaust manifold gasket.

    GFD838774Courtesy of FORD MOTOR COMPANY
  121. Install the exhaust manifold and the new nuts.

    Torque: Stage 1: 19 Nm Stage 2: 25 Nm

    GFD838775Courtesy of FORD MOTOR COMPANY
  122. Install the RH exhaust manifold heat shield and the bolts.

    Torque: 12 Nm

    GFD838653Courtesy of FORD MOTOR COMPANY
  123. Install the RH lift eye and the bolts.

    Torque: 24 Nm

    GFD838652Courtesy of FORD MOTOR COMPANY
  124. Install a new oil filter adapter gasket.
    GFD838776Courtesy of FORD MOTOR COMPANY
  125. Install the oil filter adapter and the bolts finger-tight.
    GFD838650Courtesy of FORD MOTOR COMPANY
  126. Tighten the bolt.

    Torque: 42 Nm

    GFD838242Courtesy of FORD MOTOR COMPANY
  127. Tighten the bolts in sequence shown.

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

    GFD838243Courtesy of FORD MOTOR COMPANY
  128. 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

    GFD838244Courtesy of FORD MOTOR COMPANY
    • Install the exhaust manifold studs.

      Torque: 12 Nm

    • Install the exhaust manifold gasket.

    GFD838777Courtesy of FORD MOTOR COMPANY
  130. Install the exhaust manifold and the new nuts.

    Torque: Stage 1: 19 Nm Stage 2: 25 Nm

    GFD838778Courtesy of FORD MOTOR COMPANY
  131. Install the exhaust manifold heat shield and the bolts.

    Torque: 12 Nm

    GFD838647Courtesy of FORD MOTOR COMPANY
  132. Install the generator stud bolt.

    Torque: 8 Nm

    GFD838029Courtesy of FORD MOTOR COMPANY
  133. Install the generator, nut and bolt.

    Torque: 47 Nm

    GFD838028Courtesy of FORD MOTOR COMPANY
  134. NOTE: Installation of new seals is only required if damaged seals were removed.

    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.

    GFD837880Courtesy of FORD MOTOR COMPANY
  135. NOTE: Installation of new seals is only required if damaged seals were removed.

    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.

    GFD837881Courtesy of FORD MOTOR COMPANY
  136. 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. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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

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

    GFD838779Courtesy of FORD MOTOR COMPANY
  137. Install a new valve cover gasket.
    GFD838531Courtesy of FORD MOTOR COMPANY
  138. Install the valve cover and tighten the bolts.

    Torque: 10 Nm

    GFD838780Courtesy of FORD MOTOR COMPANY
  139. 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.
    GFD837885Courtesy of FORD MOTOR COMPANY
  140. Install the RH coil-on-plugs and the bolts.

    Torque: Stage 1: 7 Nm Stage 2: 50deg.

    GFD838645Courtesy of FORD MOTOR COMPANY
  141. NOTE: Installation of new seals is only required if damaged seals were removed.

    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.

    GFD838521Courtesy of FORD MOTOR COMPANY
  142. NOTE: Installation of new seals is only required if damaged seals were removed.

    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.

    GFD838522Courtesy of FORD MOTOR COMPANY
  143. 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. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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

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

    GFD838781Courtesy of FORD MOTOR COMPANY
  144. Install a new valve cover gasket.
    GFD838524Courtesy of FORD MOTOR COMPANY
  145. Install the valve cover and tighten the bolts.

    Torque: 10 Nm

    GFD838782Courtesy of FORD MOTOR COMPANY
  146. 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.
    GFD837869Courtesy of FORD MOTOR COMPANY
    • Install the LH coil-on-plugs and the bolts.

      Torque: Stage 1: 7 Nm Stage 2: 50deg.

    • Install the oil level indicator.

    GFD838641Courtesy of FORD MOTOR COMPANY
  148. Install the brake vacuum tube bracket and the nuts.

    Torque: 7 Nm

    GFD838640Courtesy of FORD MOTOR COMPANY
  149. NOTE: Only rotate the crankshaft clockwise or damage to the engine may occur.
    NOTE: The drive lobe for the high-pressure fuel pump must be at BDC for the high-pressure fuel pump installation.

    Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC.

    GFD838783Courtesy of FORD MOTOR COMPANY
  150. Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and the roller tappet and install the high-pressure fuel pump roller tappet.
    GFD838784Courtesy of FORD MOTOR COMPANY
    • Install a new high-pressure fuel pump O-ring seal.

    • Lubricate with clean engine oil.

    GFD838785Courtesy of FORD MOTOR COMPANY
  152. Inspect the high-pressure fuel pump mounting plate O-ring seals, clean and replace as needed. Lubricate with clean engine oil.
    GFD838786Courtesy of FORD MOTOR COMPANY
  153. Inspect the high-pressure fuel pump mounting plate seal, clean and replace as needed. Lubricate with clean engine oil.
    GFD838787Courtesy of FORD MOTOR COMPANY
  154. Install the high-pressure fuel pump mounting plate on to the high-pressure fuel pump and install the high-pressure fuel pump bolts.
    GFD838788Courtesy of FORD MOTOR COMPANY
    1. Install the high-pressure fuel pump with the mounting plate, and finger tighten the high-pressure fuel pump bolts. Finger tighten the mounting plate bolt. Alternately tighten each high-pressure fuel pump bolt one complete revolution until seated. Tighten the fuel high-pressure fuel pump bolts in the following 2 stages.

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

    2. Tighten the high-pressure fuel pump mounting plate bolt.

      Torque: 12 Nm

    GFD838789Courtesy of FORD MOTOR COMPANY
    • Remove the crankshaft pulley bolt and washer.

    • Discard the bolt.

    GFD838790Courtesy of FORD MOTOR COMPANY
    • Install the new fuel rail high-pressure fuel tube and finger tight the flare nuts.

    • Install the new high-pressure fuel pump to direct injection fuel rail tube nut finger tight.

    • Tighten the fuel rail high-pressure fuel tube flare nuts.

      Torque: Stage 1: 8 Nm Stage 2: 10 Nm Stage 3: If the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 75 Nm (55 lb-ft), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.: 30deg.

    • Tighten the high-pressure fuel pump to direct injection fuel rail tube nut.

      Torque: 7 Nm

    GFD838791Courtesy of FORD MOTOR COMPANY
    • Install the engine wiring harness and attach the wiring harness retainers.

    • Connect the ignition coil-on-plug electrical connectors.

    • Connect the VCT oil control solenoids electrical connectors.

    GFD838633Courtesy of FORD MOTOR COMPANY
  159. Connect the oil pressure control solenoid, EGR valve electrical connectors and attach the wiring harness retainers.
    GFD838632Courtesy of FORD MOTOR COMPANY
    • Connect the port injector fuel rail electrical connectors.

    • Attach the wiring harness retainer.

    • Connect the FRP temperature sensor electrical connector.

    GFD838631Courtesy of FORD MOTOR COMPANY
    • Attach the wiring harness retainers.

    • Connect the oil pressure switch electrical connector.

    • Connect the ignition coil-on-plug electrical connectors.

    • Connect the VCT oil control solenoids electrical connectors.

    • Connect the high-pressure fuel pump electrical connector.

    GFD838630Courtesy of FORD MOTOR COMPANY
    • Attach the wiring harness retainers.

    • Connect the direct injection fuel rail electrical connectors.

    • Connect the CMP sensor electrical connectors.

    • Connect the KS and CHT sensor electrical connectors.

    GFD838629Courtesy of FORD MOTOR COMPANY
  163. Install the high-pressure fuel pump bracket and the bolts.

    Torque: 15 Nm

    GFD838628Courtesy of FORD MOTOR COMPANY
  164. NOTE: The high-pressure fuel pump supply tube must be installed with the Oetiker® clamp end installed to the port fuel rail; if it is installed backwards a check valve will prevent the engine from running properly.

    Follow directions to connect the quick release coupling type 2. Install the high-pressure fuel pump to port injection fuel rail tube and connect the quick release couplings.

    GFD838627Courtesy of FORD MOTOR COMPANY
    • Install the CKP sensor and the bolt.

      Torque: 6 Nm

    • Connect the CKP sensor electrical connector.

    GFD838626Courtesy of FORD MOTOR COMPANY
  166. Install the wiring harness grommet.
    GFD838625Courtesy of FORD MOTOR COMPANY
  167. Install the wiring harness retainer stud bolt.

    Torque: 10 Nm

    GFD838624Courtesy of FORD MOTOR COMPANY
  168. Install the heat shield, nut and bolt.

    Torque: 10 Nm

    GFD838623Courtesy of FORD MOTOR COMPANY
  169. Install a new thermostat housing O-ring seal.
    GFD838792Courtesy of FORD MOTOR COMPANY
  170. Install the thermostat housing and the bolts.

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

    GFD838793Courtesy of FORD MOTOR COMPANY
  171. 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 for damage or metal debris.

    GFD838509Courtesy of FORD MOTOR COMPANY
  172. Install the upper intake manifold and the bolts.

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

    GFD838794Courtesy of FORD MOTOR COMPANY
  173. Connect the MAPT sensor electrical connector and wiring harness retainers.
    GFD838619Courtesy of FORD MOTOR COMPANY
  174. Follow directions to connect the quick release coupling type 3. Install the PCV tube.
    GFD838618Courtesy of FORD MOTOR COMPANY
    • Install the upper intake manifold support bracket and the bolts.

      Torque: 10 Nm

    • NOTE: When connecting the throttle body electrical connector engage the red connector locking tab after fully installing the throttle body electrical connector. The red tab will not slide forward unless the throttle body electrical connector is fully installed.

      Connect the throttle body electrical connector and attach the wire harness retainer.

    GFD838617Courtesy of FORD MOTOR COMPANY
  176. Install the EGR valve mounting bracket and hand tighten the nut at this stage.
    GFD838795Courtesy of FORD MOTOR COMPANY
  177. Install the mounting bracket bolts.

    Torque: 10 Nm

    GFD838796Courtesy of FORD MOTOR COMPANY
  178. Install the EGR valve and the bolts to the mounting bracket.

    Torque: 10 Nm

    GFD838797Courtesy of FORD MOTOR COMPANY
  179. Loosen the EGR valve mounting bracket bolts.
    GFD838798Courtesy of FORD MOTOR COMPANY
    • Install new EGR tube O-ring seal and gasket.

    • Lubricate the O-ring seal with clean engine oil.

    GFD838799Courtesy of FORD MOTOR COMPANY
    1. Install the EGR outlet tube and the bolts finger tight.
    2. Install the bolts finger tight.
    GFD838613Courtesy of FORD MOTOR COMPANY
    1. Tighten the EGR outlet tube bolts.
    2. Tighten the bolts.
    GFD838800Courtesy of FORD MOTOR COMPANY
    1. Tighten the EGR valve bracket bolts.

      Torque: 10 Nm

    2. Tighten the EGR valve bracket nut.

      Torque: 8 Nm

    GFD838801Courtesy of FORD MOTOR COMPANY
  184. Connect the EGR valve electrical connector and attach the retainer to the EGR valve mounting bracket.
    GFD838802Courtesy of FORD MOTOR COMPANY
    • Install the differential pressure sensor and the bolt.

      Torque: 10 Nm

    • Connect the differential pressure sensor hoses.

    • Connect the wiring harness electrical connector.

    GFD838612Courtesy of FORD MOTOR COMPANY
    1. NOTE: Apply anti-seize to the EGR exhaust manifold tube nut threads before installation.

      Install a new gasket and install the EGR inlet tube and the bolts finger tight.

      Material: Anti-Seize Lubricant

    2. Install the EGR inlet tube nut finger tight.
    3. Install the EGR inlet tube bolt finger tight.
    GFD838803Courtesy of FORD MOTOR COMPANY
    1. Tighten the EGR inlet tube and the bolts.

      Torque: 10 Nm

    2. Tighten the EGR inlet tube nut.

      Torque: 40 Nm

    3. Install the EGR inlet tube bolt.

      Torque: Stage 1: 20 Nm Stage 2: 45deg.

    GFD838804Courtesy of FORD MOTOR COMPANY
  188. Follow directions to connect the quick release coupling type 3. Install the crankcase vent tube. Refer to: Quick Release Coupling .
    GFD838609Courtesy of FORD MOTOR COMPANY
    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

    GFD838608Courtesy of FORD MOTOR COMPANY
  190. Lubricate the crankshaft front seal bore with clean engine oil.
    GFD838340Courtesy of FORD MOTOR COMPANY
  191. Using the special tools, install the crankshaft front seal.Use Special Service Tool: 303-102 Installer, Crankshaft Pulley., 303-1251 Installer, Front Seal.
    GFD838805Courtesy of FORD MOTOR COMPANY
  192. Lubricate the crankshaft pulley with clean engine oil.
    GFD838344Courtesy of FORD MOTOR COMPANY
  193. 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.
    GFD838806Courtesy of FORD MOTOR COMPANY
  194. NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).

    With the aid of an assistant, using a universal pulley holder, install and tighten a new crankshaft pulley bolt and the washer and tighten in 3 stages.

    Torque: Stage 1: 50 Nm Stage 2: 90deg. Stage 3: 60deg.

    GFD838807Courtesy of FORD MOTOR COMPANY
  195. Install the coolant tube and retainer.
    GFD838604Courtesy of FORD MOTOR COMPANY
  196. Install the RH engine mount bracket and the bolts.

    Torque: 63 Nm

    GFD838603Courtesy of FORD MOTOR COMPANY
  197. Install the LH engine mount bracket and the bolts.

    Torque: 63 Nm

    GFD838602Courtesy of FORD MOTOR COMPANY
  198. If equipped with block heater, install and connect the block heater electrical connector and retainer.
    GFD838601Courtesy of FORD MOTOR COMPANY
  199. If equipped with block heater, install the block heater cover.
    GFD838600Courtesy of FORD MOTOR COMPANY
  200. Install the LH engine lift eye.Install Special Service Tool: 303-1245 Engine Lift Eye.
    GFD838593Courtesy of FORD MOTOR COMPANY
  201. Install the floor crane.Use the General Equipment: Floor Crane
    GFD838594Courtesy of FORD MOTOR COMPANY
  202. Remove the engine from the mounting stand.Use the General Equipment: Mounting Stand
    GFD838599Courtesy of FORD MOTOR COMPANY
  203. Inspect the engine block dowels. If the dowels are damaged or missing, install new engine block dowels.
    GFD838352Courtesy of FORD MOTOR COMPANY
  204. Inspect the ignition pulse ring for damage. If the ignition pulse ring has been dropped or has any visual damage, it must be replaced.
    GFD838353Courtesy of FORD MOTOR COMPANY
  205. NOTE: Make sure the crankshaft ignition pulse ring is aligned with the inset hole on the crankshaft flange.

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

    GFD838598Courtesy of FORD MOTOR COMPANY
  206. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.

    • Install the flexplate aligning it with the offset hole and hand start bolts 5, 6, 7 and 8.

    • Tighten the bolts 5, 6, 7 and 8 in sequence one turn at a time until the flexplate is snug against the rear face of the crankshaft.

    • Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

    • Torque the bolts 5, 6, 7 and 8 in sequence.

      Torque: 80 Nm

    • Install the bolts 1, 2, 3 and 4 finger tight.

    • Torque the bolts 1, 2, 3 and 4 in sequence.

      Torque: 80 Nm

    • Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

GFD838425Courtesy of FORD MOTOR COMPANY
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