Section 58 (Engine - 5.4L (3V) - F250-F550 Super Duty): Assembly: Engine

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOLS

	Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
	Installer, Connecting Rod 303-442 (T93P-6136-A)
	Compressor, Valve Spring 303-1039
	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
	Installer, Crankshaft Front Seal 303-635
	Installer, Front Cover Seal 303-335 (T88T-6701-A)
	Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
	Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH)
	Installer, Crankshaft Oil Slinger 303-517 (T95P-6701-CH)
	Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH)
	Impact Slide Hammer 100-001 (T50T-100-A)
	Alignment Pins, Cylinder Head 303-1040 (SR-015486)
	Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
	Locking Tool, Camshaft Phaser Sprocket 303-1046
	Holding Tool, Crankshaft 303-448 (T93P-6303-A)

MATERIAL

Item	Specification
Motorcraft Metal Surface Prep ZC-31	-
Silicone Gasket Remover ZC-30	-
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W-20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent	WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent (yellow color)	WSS-M97B51-A1
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA	-

Fig 1: Exploded View Of Engine - Upper End (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Engine - Upper End (2 Of 2)

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Engine - Front End

Courtesy of FORD MOTOR CO.

Fig 4: Exploded View Of Engine - Lower End (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 5: Exploded View Of Engine - Lower End (2 Of 2)

Courtesy of FORD MOTOR CO.

Record the main bearing code found on the front of the engine block.

Fig 6: Identifying Main Bearing Code Location (Engine Block)
Courtesy of FORD MOTOR CO.
Record the main bearing code found on the back of the crankshaft.

Fig 7: Identifying Main Bearing Code - Found On Back Of Crankshaft
Courtesy of FORD MOTOR CO.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
- 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 for the number 1 crankshaft main bearing.
- As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2".
- Repeat this process for the remaining 4 main bearings.
Fig 8: Bearing Select Fit Chart (Standard Bearings)
Courtesy of FORD MOTOR CO.
If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.

Fig 9: Bearing Select Fit Chart (Oversized Bearings)
Courtesy of FORD MOTOR CO.

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.

Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.

NOTE: The upper thrust washers are shown for location purposes only. Do not install the upper thrust washers until the crankshaft is installed. Refer to the following 2 steps.

Fig 10: Installing Crankshaft Onto Upper Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

Install the crankshaft onto the upper crankshaft main bearings.

NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).

Fig 11: Installing Rear Crankshaft Upper Thrust Washer

Courtesy of FORD MOTOR CO.

Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.

NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).

Fig 12: Installing Front Crankshaft Upper Thrust Washer

Courtesy of FORD MOTOR CO.

Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.

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

NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).

Fig 13: Installing Lower Crankshaft Thrust Washer

Courtesy of FORD MOTOR CO.

Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
Install the dowel pins so the flat sides face the crankshaft.

Fig 14: Installing Dowel Pins
Courtesy of FORD MOTOR CO.
Install the vertical main bearing cap fasteners and tighten in 2 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 15: Installing Vertical Main Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Install the side bolts and tighten them in 2 stages, in the sequence shown.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 16: Identifying Side Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.
Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
Assemble the 8 pistons. For additional information, refer to PISTON .
Make sure the ring gaps (oil spacer - A, oil ring - B, compression ring - C) are correctly spaced around the circumference of the piston.

Fig 17: Identifying Ring Gap Positioning
Courtesy of FORD MOTOR CO.

CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only one connecting rod, rod bearing and piston is shown.

Use the special tools to install the connecting rod with the upper connecting rod bearing in place.
- Lubricate the piston and ring with clean engine oil.
- Lubricate the rod bearings with clean engine oil.
  
  Fig 18: Installing Connecting Rod With Upper Connecting Rod Bearing In Place
  Courtesy of FORD MOTOR CO.

CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Fig 19: Removing Special Tool

Courtesy of FORD MOTOR CO.

Once the connecting rod is seated on the crankshaft journal, remove the special tool.

CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod, and install the new bolts loosely.

NOTE: Main bearing caps are removed for clarity.

Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 43 Nm (32 lb-ft).
- Stage 2: Tighten an additional 105 degrees.
  
  Fig 20: Tightening Connecting Rod Cap Bolts
  Courtesy of FORD MOTOR CO.
Position the oil pump and install the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 21: Identifying Oil Pump Bolts
  Courtesy of FORD MOTOR CO.
Install the oil pump screen and pickup tube spacer.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 22: Installing Oil Pump Screen And Pickup Tube Spacer
  Courtesy of FORD MOTOR CO.

CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil prior to installation.

Position the oil pump screen and pickup tube and install the bolts.
- Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
- Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
  
  Fig 23: Tightening Oil Pump Screen
  Courtesy of FORD MOTOR CO.
Position the crankshaft with the special tool, then remove the tool.

Fig 24: Positioning Crankshaft With Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Fig 25: Using Special Tools, Position Cylinder Head Gaskets And Cylinder Heads Over Dowels And Install Cylinder Head Bolts Loosely

Courtesy of FORD MOTOR CO.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.

NOTE: Tighten the bolts in 3 stages, in the sequence shown.

RH shown, LH similar.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 26: Identifying Cylinder Head Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.
Remove the special tool from the LH cylinder head.

Fig 27: Installing Special Tool Onto LH Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the special tool from the RH cylinder head.

Fig 28: Installing Special Tool Onto RH Cylinder Head
Courtesy of FORD MOTOR CO.
Install the hydraulic lash adjusters into the RH and LH cylinder heads.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  
  Fig 29: Identifying Hydraulic Lash Adjusters
  Courtesy of FORD MOTOR CO.
Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

NOTE: LH shown, RH similar.

Install the LH and RH camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the front camshaft bearing cap.
- Position the remaining camshaft bearing caps.
- Install the bolts loosely.
- Tighten to 10 Nm (89 lb-in) in the sequence shown.
  
  Fig 30: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequences
  Courtesy of FORD MOTOR CO.

CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: LH shown, RH similar.

Fig 31: Identifying Camshaft Phaser Sprocket Bolt

Courtesy of FORD MOTOR CO.

Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight.

CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

CAUTION: Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.

NOTE: LH shown, RH similar.

Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages.
- Stage 1: Tighten to 40 N.m (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 32: Identifying Special Sprocket Phase Tool

Courtesy of FORD MOTOR CO.

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Failure to follow these instructions may result in engine damage.

Compress the tensioner plunger, using a vise.

Fig 33: Compressing Tensioner Plunger

Courtesy of FORD MOTOR CO.

Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 34: Identifying Retaining Clip on Tensioner

Courtesy of FORD MOTOR CO.

Remove the tensioner from the vise.
If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.

Fig 35: Locating Timing Chain Marks

Courtesy of FORD MOTOR CO.

Install the crankshaft sprocket, making sure the flange faces forward.

Fig 36: Identifying Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Install the 4 bolts and the LH and RH timing chain guides.
- Tighten to 10 N.m (89 lb-in).

Fig 37: Identifying Timing Chain Guides

Courtesy of FORD MOTOR CO.

Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.

Fig 38: Aligning Crankshaft Sprocket Timing Mark And LH Timing Chain Link

Courtesy of FORD MOTOR CO.

NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.

Fig 39: Identifying Copper Links Of Timing Chain On VCT Phaser Sprocket

Courtesy of FORD MOTOR CO.

NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
- Tighten to 25 N.m (18 lb-ft).

Fig 40: Identifying LH Timing Chain Tensioner & Tensioner Arm

Courtesy of FORD MOTOR CO.

Remove the retaining clip from the LH timing chain tensioner.

Fig 41: Identifying Retaining Clip And Timing Chain Tensioner

Courtesy of FORD MOTOR CO.

Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.

Fig 42: Aligning Crankshaft Sprocket Timing Mark And RH Timing Chain Link

Courtesy of FORD MOTOR CO.

NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.

NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.

Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.

Fig 43: Positioning RH Timing Chain On Camshaft Sprocket

Courtesy of FORD MOTOR CO.

Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
- Tighten to 25 N.m (18 lb-ft).

Fig 44: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts

Courtesy of FORD MOTOR CO.

Remove the retaining clip from the RH timing chain tensioner.

Fig 45: Identifying Retaining Clip And Timing Chain Tensioner

Courtesy of FORD MOTOR CO.

As a post-check, verify correct alignment of all timing marks.

Fig 46: Locating Timing Marks

Courtesy of FORD MOTOR CO.

Install the crankshaft sensor ring on the crankshaft.

Fig 47: Locating Crankshaft Sensor Ring At Crankshaft

Courtesy of FORD MOTOR CO.

CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage.

Using the special tool, install all of the camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.

Fig 48: Compressing Spring Using Special Tool (303-1039)

Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: If the engine front cover is not secured 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. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.

Fig 49: Applying Bead Of Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.

Fig 50: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.
Tighten the engine front cover fasteners in sequence in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Fig 51: Tightening Engine Front Cover Fasteners
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the LH camshaft position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 52: Locating Bolt And LH CMP Sensor
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 53: Identifying Bolt And RH CMP Sensor
  Courtesy of FORD MOTOR CO.

CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Position the coolant pump and install the bolts loosely.
- Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
  
  Fig 54: Identifying Coolant Pump
  Courtesy of FORD MOTOR CO.
Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 55: Identifying Coolant Pump Bolts
  Courtesy of FORD MOTOR CO.
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 56: Installing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install a new crankshaft front seal into the engine front cover.

Fig 57: Installing Crankshaft Front Seal Using Special Tools
Courtesy of FORD MOTOR CO.

NOTE: If not secured 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. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Fig 58: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
Use the special tool to install the crankshaft pulley.

Fig 59: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
  
  Fig 60: Installing Crankshaft Pulley Bolt & Washer
  Courtesy of FORD MOTOR CO.
Position the crankshaft position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 61: Locating Crankshaft Position (CKP) Sensor And Bolt
  Courtesy of FORD MOTOR CO.
Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 62: Identifying Accessory Drive Belt Tensioner Bolts
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 63: Identifying Coolant Pump Pulley and Idler Pulley Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts and the nut.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 64: Positioning Oil Filter Adapter
  Courtesy of FORD MOTOR CO.
Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 65: Identifying Bolt Tightening/Loosening Sequence Of LH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Install the LH engine support insulator and the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).
  
  Fig 66: Installing LH Engine Support Insulator
  Courtesy of FORD MOTOR CO.
Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 67: Identifying Bolt Tightening/Loosening Sequence Of RH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Install the RH engine support insulator bracket and the 4 bolts.
- Tighten to 63 Nm (46 lb-ft).
  
  Fig 68: Installing RH Engine Support Insulator Bracket
  Courtesy of FORD MOTOR CO.
Install the RH engine support insulator and the 4 bolts.
- Tighten to 63 Nm (46 lb-ft).
  
  Fig 69: Installing RH Engine Support Insulator
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Fig 70: Identifying Silicone Gasket Application Points

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.

Position the RH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 71: Identifying Tighten Sequence Of LH Valve Cover Bolts
  Courtesy of FORD MOTOR CO.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Fig 72: Identifying Silicone Gasket Application Points

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.

Position the LH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 73: Identifying Tighten Sequence Of RH Valve Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Do not reuse the O-ring seals.

NOTE: Lubricate the new O-ring seals with clean engine coolant prior to installation.

Fig 74: Installing Heater Outlet Tube Over New Seals

Courtesy of FORD MOTOR CO.

Slide the coolant tube forward with the new O-ring seals into the cylinder block.
Install the coolant tube stud bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 75: Identifying Coolant Tube Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the 2 knock sensors (KS) and the bolts.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 76: Identifying Knock Sensors (KS)
  Courtesy of FORD MOTOR CO.
Install the oil level indicator tube and the front bolt.
- Tighten to 25 Nm (18 lb-ft).
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.
  
  Fig 77: Locating Front Oil Level Indicator Tube Bolt
  Courtesy of FORD MOTOR CO.
Install the rear oil level indicator tube bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 78: Locating Rear Oil Level Indicator Tube Bolt
  Courtesy of FORD MOTOR CO.
Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.

NOTE: LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 79: Identifying Ignition Coils And Bolts
  Courtesy of FORD MOTOR CO.
Install the LH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 80: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
  Courtesy of FORD MOTOR CO.
Connect the cylinder head temperature (CHT) sensor electrical connector.

Fig 81: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 4 RH ignition coil electrical connectors.

Fig 82: Locating RH Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the 2 engine wiring harness retainers from the RH valve cover studs.

Fig 83: Locating Engine Wiring Harness Retainers To RH Valve Cover
Courtesy of FORD MOTOR CO.
Connect the RH VCT solenoid electrical connector.

Fig 84: Locating RH VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Install the RH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 85: Identifying RH Radio Ignition Interference Capacitor And Stud Bolt
  Courtesy of FORD MOTOR CO.
Connect the RH CMP sensor electrical connector.

Fig 86: Identifying RH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Position a new oil cooler and install the threaded shaft.
- Tighten to 58 Nm (43 lb-ft).
  
  Fig 87: Identifying Threaded Shaft
  Courtesy of FORD MOTOR CO.
Connect the coolant hoses to the oil cooler.

Fig 88: Connecting Coolant Hoses To Oil Cooler
Courtesy of FORD MOTOR CO.
Connect the lower radiator hose to the oil filter adapter.

Fig 89: Connecting Lower Radiator Hose To Oil Filter Adapter
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 90: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Using a suitable floor crane, remove the engine from the engine stand.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Fig 91: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface

Courtesy of FORD MOTOR CO.

Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.

Fig 92: Identifying Crankshaft Rear Oil Seal Retainer
Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 93: Identifying Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Fig 94: Identifying Area For Applying Bead Of Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.

Fig 95: Identifying Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
Install the oil pan gasket and the oil pan and loosely install the bolts.

Fig 96: Identifying Oil Pan And Gasket
Courtesy of FORD MOTOR CO.
Tighten the bolts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 20 Nm (15 lb-ft).
- Stage 3: Tighten an additional 60 degrees.
  
  Fig 97: Identifying Oil Pan Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Fig 98: Installing Crankshaft Rear Oil Seal

Courtesy of FORD MOTOR CO.

Using the special tools, install a new crankshaft rear seal.
Using the special tools, install a new crankshaft rear oil slinger.

Fig 99: Installing Crankshaft Rear Oil Slinger
Courtesy of FORD MOTOR CO.
Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
  
  Fig 100: Identifying Flywheel/Flexplate Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.