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Section 1500 (Engine - 2.0L DURATEC-He (125KW/170PS) - Mi4): Assembly: Engine

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Special Tool(s) / General Equipment 

GFD265614Courtesy of FORD MOTOR COMPANY
 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
GFD265615Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W) Handle
GFD265616Courtesy of FORD MOTOR COMPANY
 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F
GFD265617Courtesy of FORD MOTOR COMPANY
 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F
GFD265618Courtesy of FORD MOTOR COMPANY
 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD265619Courtesy of FORD MOTOR COMPANY
 303-1252 Stretchy Belt Remover/ Installer Tool TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD265620Courtesy of FORD MOTOR COMPANY
 303-1521 Alignment Tool, Crankshaft Position Sensor TKIT-2010C-FLM
GFD265621Courtesy of FORD MOTOR COMPANY
 303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM
GFD265622Courtesy of FORD MOTOR COMPANY
 303-1567 Sizer, Teflon Seal TKIT-2010C-FLM
GFD265623Courtesy of FORD MOTOR COMPANY
 303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-FLM TKIT-1988-F TKIT-1988-LM
GFD265624Courtesy of FORD MOTOR COMPANY
 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW
GFD265625Courtesy of FORD MOTOR COMPANY
 303-D032 (D81L-6002-C) Compressor, Piston Ring
GFD265626Courtesy of FORD MOTOR COMPANY
 303-D055 (D85L-6000-A) Strap Wrench
GFD265627Courtesy of FORD MOTOR COMPANY
 310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM
Hose Clamp Remover/Installer
Round-Ended Steel Rule

Materials 

Name Specification
Flange Sealant CU7Z-19B508-A WSS-M2G348-A11
Motorcraft® Metal Surface Prep Wipes ZC-31-B -
Motorcraft® Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil XO-5W20-Q1SP WSS-M2C945-B1
Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.
NOTE: Refer to exploded views in DESCRIPTION AND OPERATION .
  1. NOTE: If the oil coolers are being reused, they must be installed in the same location as marked during disassembly.
    NOTE: The front bulkhead does not have an engine piston oil cooler.

    Install the engine piston oil coolers.

    Torque

    : 35 lb.in (4 Nm)

    GFD265628Courtesy of FORD MOTOR COMPANY
  2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
    GFD265629Courtesy of FORD MOTOR COMPANY
  3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.
    GFD265630Courtesy of FORD MOTOR COMPANY
  4. Tighten the original main bearing beam bolts.

    Torque

    :Stage 1: 44 lb.in (5 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 90°

    Fig 1: Main Bearing Cap Beam Bolts Tightening Sequence
    GFD265631Courtesy of FORD MOTOR COMPANY
  5. Measure each crankshaft block main bearing bore diameter.
    GFD265632Courtesy of FORD MOTOR COMPANY
  6. Using the chart, select the crankshaft main bearings.
    GFD265633Courtesy of FORD MOTOR COMPANY
  7. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 2 stages:

    Torque

    :Stage 1: 21 lb.ft (29 Nm) Stage 2: 90°

    GFD265634Courtesy of FORD MOTOR COMPANY
    • Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.

    • Remove the bolts and the connecting rod cap.

    • Discard the connecting rod cap bolts.

    GFD265635Courtesy of FORD MOTOR COMPANY
  9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
    GFD265636Courtesy of FORD MOTOR COMPANY
  10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    GFD265637Courtesy of FORD MOTOR COMPANY
  11. NOTE: Discard the main bearing beam bolts.

    Remove the 10 bolts in the sequence shown and the main bearing beam.

    GFD265638Courtesy of FORD MOTOR COMPANY
  12. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
    NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
    NOTE: The center bulkhead is the thrust bearing.

    Lubricate and install the upper crankshaft main bearings.

    Material

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

    GFD265639Courtesy of FORD MOTOR COMPANY
  13. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

    Lubricate and install the lower crankshaft main bearings.

    Material

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

    GFD265640Courtesy of FORD MOTOR COMPANY
  14. Lubricate and install the crankshaft.

    Material

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

    GFD265641Courtesy of FORD MOTOR COMPANY
  15. Lubricate the main bearing beam.

    Material

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

    GFD265642Courtesy of FORD MOTOR COMPANY
  16. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    GFD265643Courtesy of FORD MOTOR COMPANY
  17. NOTE: Lubricate the main bearing beam bolt threads and under the bolt heads with clean engine oil.
    NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

    Install new main bearing beam bolts.

    Material

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

    Torque

    :Stage 1: 44 lb.in (5 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 90°

    GFD265644Courtesy of FORD MOTOR COMPANY
    • Measure crankshaft end play. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    • Position the crankshaft to the rear of the cylinder block.

    • Zero the Dial Indicator Gauge with Holding Fixture.

    • Move the crankshaft to the front of the cylinder block.

    • Note and record the crankshaft end play.

    • Acceptable crankshaft end play is 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.

    GFD265645Courtesy of FORD MOTOR COMPANY
  19. Piston to be assembled with the arrow pointing to the front of the engine.
    GFD265646Courtesy of FORD MOTOR COMPANY
  20. Connecting rod to be assembled with the front marks pointing to the front of the engine.
    GFD265647Courtesy of FORD MOTOR COMPANY
  21. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
    NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
    NOTE: When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation.

    Using the Piston ring Compressor, lubricate with clean engine oil and install the pistons. Use Special Service Tool: 303-D032 (D81L-6002-C) Compressor, Piston Ring.

    Material

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

    GFD265648Courtesy of FORD MOTOR COMPANY
  22. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
    NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

    Install the connecting rod caps and the new bolts and tighten the bolts in 2 stages:

    Torque

    :Stage 1: 21 lb.ft (29 Nm) Stage 2: 90°

    GFD265649Courtesy of FORD MOTOR COMPANY
  23. Install the special tool and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    GFD265650Courtesy of FORD MOTOR COMPANY
  24. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
  25. NOTE: Clean the oil pump and cylinder block mating surfaces with Motorcraft Metal Surface Prep.

    Install the oil pump and the bolts.

    Material

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

    Torque

    :Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm)

    GFD265651Courtesy of FORD MOTOR COMPANY
  26. Install the oil pump sprocket and the bolt.

    Torque

    : 18 lb.ft (25 Nm)

    GFD265652Courtesy of FORD MOTOR COMPANY
  27. NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    Identify crankshaft sprocket type.

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

      NOT  require diamond washers).

    GFD265653Courtesy of FORD MOTOR COMPANY
  28. NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
    NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, install the diamond washer.

    GFD265654Courtesy of FORD MOTOR COMPANY
  29. Install the crankshaft sprocket.
    GFD265655Courtesy of FORD MOTOR COMPANY
    1. Install the chain on the oil pump sprocket and install the tensioner and the 2 shoulder bolts.

      Torque

      : 89 lb.in (10 Nm)

    2. Push the tensioner spring down and position the spring under the shoulder bolt.
    GFD265656Courtesy of FORD MOTOR COMPANY
  31. Position the crankshaft rear oil seal with retainer plate onto the crankshaft. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.

    Torque

    : 89 lb.in (10 Nm)

    GFD265657Courtesy of FORD MOTOR COMPANY
  32. NOTE: Install a new gasket.

    Install the oil pickup and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265658Courtesy of FORD MOTOR COMPANY
  33. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

    Apply sealant to the oil pan flange.

    Material

    : Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    GFD265659Courtesy of FORD MOTOR COMPANY
  34. Finger-tight.
    GFD265660Courtesy of FORD MOTOR COMPANY
  35. Align the front surface of the oil pan flush with the front surface of the engine block. Use the General Equipment: Round-Ended Steel Rule
    GFD265661Courtesy of FORD MOTOR COMPANY
  36. Tighten the bolts.

    Torque

    : 177 lb.in (20 Nm)

    GFD265662Courtesy of FORD MOTOR COMPANY
  37. Install the cylinder head dowels.
    GFD265663Courtesy of FORD MOTOR COMPANY
  38. Install a new gasket.
    GFD265664Courtesy of FORD MOTOR COMPANY
  39. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

    Install the cylinder head and the bolts.

    Torque

    :Stage 1: 62 lb.in (7 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 26 lb.ft (35 Nm) Stage 4: 90° Stage 5: 135°

    GFD265665Courtesy of FORD MOTOR COMPANY
  40. Install the 16 valve tappets in their original positions.

    Material

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

    GFD265666Courtesy of FORD MOTOR COMPANY
  41. NOTE: The exhaust camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the exhaust camshaft rear bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.
    NOTE: Do not allow Gasket Maker to enter the camshaft bearing journal. If Gasket Maker is applied to the camshaft bearing journal, the journal and sealing area must be cleaned with Motorcraft Metal Surface Prep.

    Apply a 1 mm (0.039 in) bead of sealant.

    Material

    : Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    GFD265667Courtesy of FORD MOTOR COMPANY
  42. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.

    • Lubricate the camshaft journals, camshafts and camshaft bearing caps with clean engine oil and install the camshafts, caps and bolts.

    • Tighten 2 turns at a time in the sequence shown in 2 stages.

      Torque

      :Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)

    GFD265668Courtesy of FORD MOTOR COMPANY
  43. Lubricate the camshaft journals with clean engine oil and install the front camshaft bearing cap and bolts.

    Torque

    :Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)

    GFD265669Courtesy of FORD MOTOR COMPANY
  44. If camshafts were replaced, check the valve clearance. Refer to: Valve Clearance Check  .
  45. NOTE: The special tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

    Install Special Service Tool: 303-1565 Alignment Tool, Camshaft.

    GFD265670Courtesy of FORD MOTOR COMPANY
  46. NOTE: Lubricate the VCT oil control solenoids with clean engine oil.

    Install the VCT oil control solenoids and the bolts.

    Material

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

    Torque

    : 89 lb.in (10 Nm)

    GFD265671Courtesy of FORD MOTOR COMPANY
  47. NOTE: The VCT unit bolts are final torqued in the timing drive installation.

    Finger tight.

    GFD265672Courtesy of FORD MOTOR COMPANY
  48. Install the timing chain.
    GFD265673Courtesy of FORD MOTOR COMPANY
  49. Install the timing chain guide and bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265674Courtesy of FORD MOTOR COMPANY
  50. Install the timing chain arm.
    GFD265675Courtesy of FORD MOTOR COMPANY
    NOTE: If equipped with aluminum timing chain tensioner.
    NOTE: If the timing chain tensioner plunger is not pinned in the compressed position, follow the next step.
  51. Reset the timing chain tensioner.

    1. Position the timing chain tensioner in a soft-jawed vise.
    2. Spread the ends of the ratchet wire clip apart.
    3. Using the soft-jawed vise, compress the plunger to the reset position.
    4. Install a locking pin in the 2 holes of the timing chain tensioner body to hold the plunger in place.

    GFD265676Courtesy of FORD MOTOR COMPANY
  52. NOTE: If equipped with aluminum timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

    1. Install the timing chain tensioner and the bolts.

      Torque

      : 89 lb.in (10 Nm)

    2. Remove the locking pin.

    GFD265677Courtesy of FORD MOTOR COMPANY
    NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
  53. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

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

    GFD265678Courtesy of FORD MOTOR COMPANY
  54. Using a small pick, push back and hold the ratchet mechanism.
    GFD265679Courtesy of FORD MOTOR COMPANY
  55. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    GFD265680Courtesy of FORD MOTOR COMPANY
  56. Install a locking pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    GFD265681Courtesy of FORD MOTOR COMPANY
  57. NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

    Install the timing chain tensioner and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265682Courtesy of FORD MOTOR COMPANY
  58. NOTE: If equipped with cast iron timing chain tensioner.

    Remove the locking pin.

    GFD265683Courtesy of FORD MOTOR COMPANY
  59. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: Using the flats on the camshafts to prevent camshaft rotation.

    Tighten the VCT assembly bolts.

    Torque

    :Stage 1: 37 lb.ft (50 Nm) Stage 2: 90°

    GFD265684Courtesy of FORD MOTOR COMPANY
  60. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply a 15 mm (0.59 in) drop of silicone sealant at the cylinder head-to-cylinder block and cylinder block-to-oil pan joint areas.

    Material

    : Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    GFD265685Courtesy of FORD MOTOR COMPANY
  61. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.

    Apply sealant to the engine front cover.

    Material

    : Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    GFD265686Courtesy of FORD MOTOR COMPANY
    1. Install the engine front cover and the bolts finger tight.
    2. If equipped, install the bolt finger tight.
    GFD265687Courtesy of FORD MOTOR COMPANY
  63. Tighten the engine front cover bolts in sequence shown.

    Torque

    :Bolts 1 - 3: 35 lb.ft (48 Nm) Bolts 4 - 8: 89 lb.in (10 Nm) If equippped, bolt 9: 18 lb.ft (25 Nm) Bolts 10 - 14: 89 lb.in (10 Nm) Bolt 15: 35 lb.ft (48 Nm) Bolts 16 - 22: 89 lb.in (10 Nm)

    GFD265688Courtesy of FORD MOTOR COMPANY
  64. NOTE: Remove the through-bolt from the special tool.

    Install the engine front cover seal. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.

    Material

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

    GFD265689Courtesy of FORD MOTOR COMPANY
  65. NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
    NOTE: Early build engines are equipped with a diamond washers on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, install the diamond washer onto the crankshaft.

    GFD265690Courtesy of FORD MOTOR COMPANY
  66. NOTE: Do not install the crankshaft pulley bolt at this time.
    NOTE: Apply clean engine oil on the seal area before installing.

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

    Material

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

    GFD265691Courtesy of FORD MOTOR COMPANY
  67. NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

    Install a standard bolt through the crankshaft pulley TDC guide hole and into the engine front cover.

    GFD265692Courtesy of FORD MOTOR COMPANY
  68. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and a new bolt should be installed using hand tools only.
    NOTE: Do not reuse the crankshaft pulley bolt. Install a new crankshaft pulley bolt

    Tighten the crankshaft pulley bolt. Use Special Service Tool: 303-D055 (D85L-6000-A) Strap Wrench.

    Torque

    :Stage 1: 74 lb.ft (100 Nm) Stage 2: 90°

    GFD265693Courtesy of FORD MOTOR COMPANY
  69. Remove the bolt.
    GFD265694Courtesy of FORD MOTOR COMPANY
  70. Finger tight.
    GFD265695Courtesy of FORD MOTOR COMPANY
  71. Install the special tool to set the CKP sensor position and tighten the 2 bolts. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.

    Torque

    : 62 lb.in (7 Nm)

    GFD265696Courtesy of FORD MOTOR COMPANY
  72. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Clean and inspect the sealing surfaces of the valve cover.

  73. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

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

    GFD265697Courtesy of FORD MOTOR COMPANY
  74. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.

    Apply a 6 mm bead of sealant.

    Material

    : Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    GFD265698Courtesy of FORD MOTOR COMPANY
  75. NOTE: Install a new valve cover gasket.

    Install the valve cover and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265699Courtesy of FORD MOTOR COMPANY
  76. If equipped.

    Torque

    : 27 lb.in (3 Nm)

    GFD265700Courtesy of FORD MOTOR COMPANY
  77. Inspect the ignition coil boot for rips, nicks or tears. Remove and discard the damaged ignition coil boots.
    GFD265701Courtesy of FORD MOTOR COMPANY
  78. NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inside of the ignition coil-on-plug boots before installation.

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

    Material

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

    Torque

    : 89 lb.in (10 Nm)

    GFD265702Courtesy of FORD MOTOR COMPANY
  79. Install the oil level indicator.
    GFD265703Courtesy of FORD MOTOR COMPANY
  80. Install the coolant outlet and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265704Courtesy of FORD MOTOR COMPANY
  81. Install the housing and the stud bolts.

    Torque

    :Stage 1: 71 lb.in (8 Nm) Stage 2: 60°

    GFD265705Courtesy of FORD MOTOR COMPANY
  82. Install the bracket and the nuts.

    Torque

    : 177 lb.in (20 Nm)

    GFD265706Courtesy of FORD MOTOR COMPANY
  83. NOTE: The cam lobe for the fuel injection pump must be at BDC for the fuel injection pump installation.

    Lubricate and install the tappet.

    Material

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

    GFD265707Courtesy of FORD MOTOR COMPANY
  84. Install and lubricate a new O-ring seal.

    Material

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

    GFD265708Courtesy of FORD MOTOR COMPANY
  85. NOTE: Only rotate the crankshaft clockwise or damage to the engine may occur.

    Turn the crankshaft clockwise until the fuel injection pump cam lobe is at BDC.

    GFD265709Courtesy of FORD MOTOR COMPANY
  86. Install the fuel injection pump and loosely install 2 new fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated.

    Torque

    :Stage 1: 177 lb.in (20 Nm) Stage 2: 45°

    GFD265710Courtesy of FORD MOTOR COMPANY
  87. Install the bracket and the bolts.

    Torque

    : 35 lb.ft (48 Nm)

    GFD265711Courtesy of FORD MOTOR COMPANY
  88. Install the bracket and the bolts.

    Torque

    : 18 lb.ft (25 Nm)

    GFD265712Courtesy of FORD MOTOR COMPANY
  89. NOTE: The RHKS must be installed in the 6 o'clock position and the LHKS must be installed in the 4 o'clock position. Failure to follow these instructions may result in damage to the engine.

    Install the knock sensors and the bolts.

    Torque

    : 177 lb.in (20 Nm)

    GFD265713Courtesy of FORD MOTOR COMPANY
  90. NOTE: Install a new gasket.

    Install the oil filter adapter and the bolts.

    Torque

    : 18 lb.ft (25 Nm)

    GFD265714Courtesy of FORD MOTOR COMPANY
  91. NOTE: Install a new gasket.

    Install the oil separator and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265715Courtesy of FORD MOTOR COMPANY
  92. 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.
    NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

    Pull the lower Teflon® seal away from the injector with narrow tip pliers.

    GFD265716Courtesy of FORD MOTOR COMPANY
  93. Carefully cut and discard the lower fuel injector Teflon® seals.
    GFD265717Courtesy of FORD MOTOR COMPANY
  94. Place the special tool, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
    GFD265718Courtesy of FORD MOTOR COMPANY
  95. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    Install the new lower Teflon® seals on the narrow end of the Arbor (part of the special tool), then install the Arbor on the fuel injector tips. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly., 303-1567 Sizer, Teflon Seal.

    GFD265719Courtesy of FORD MOTOR COMPANY
  96. NOTE: Once the Teflon® seal is installed on the Arbor, it should immediately be installed onto the fuel injector to avoid excessive expansion of the seal.

    Using the Pusher Tool (part of the special tool), slide the Teflon® seals off of the Arbor and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly., 303-1567 Sizer, Teflon Seal.

    GFD265720Courtesy of FORD MOTOR COMPANY
  97. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the seal.

    Slide the special tool off the end of the fuel injector to size the seal. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.

    GFD265721Courtesy of FORD MOTOR COMPANY
  98. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Lubricate the upper fuel injector O-ring seals with clean engine oil.
    NOTE: Install the fuel injectors into the cylinder head within 15 minutes due to Teflon® seal expansion.

    Install the new upper fuel injector O-ring seal support rings and the new upper fuel injector O-ring seals.

    Material

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

    GFD265722Courtesy of FORD MOTOR COMPANY
  99. Install the fuel injector clips.
    GFD265723Courtesy of FORD MOTOR COMPANY
  100. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
    NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.

    Install the fuel injectors into the fuel rail.

    GFD265724Courtesy of FORD MOTOR COMPANY
  101. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    Install the fuel rail by pushing down on the fuel rail face above the injectors and install the 4 bolts.

    Torque

    : 18 lb.ft (25 Nm)

    Fig 2: Fuel Rail Bolts Tightening Sequence
    GFD265725Courtesy of FORD MOTOR COMPANY
    1. Hand tighten the high pressure fuel tube-to-fuel rail flare nut.
    2. Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.
    GFD265726Courtesy of FORD MOTOR COMPANY
  103. Finger tight.
    GFD265727Courtesy of FORD MOTOR COMPANY
  104. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas below.
    G00468730

    Tighten the high pressure fuel tube-to-fuel injection pump flare nut in the following 2 stages:

    Torque

    :Stage 1: 133 lb.in (15 Nm) Stage 2: 45°

    GFD265728Courtesy of FORD MOTOR COMPANY
  105. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas below.
    G00468730

    Tighten the high pressure fuel tube-to-fuel injection pump flare nut in the following 2 stages:

    Torque

    :Stage 1: 133 lb.in (15 Nm) Stage 2: 45°

    GFD265729Courtesy of FORD MOTOR COMPANY
  106. Tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265730Courtesy of FORD MOTOR COMPANY
  107. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.

    Install the insulator.

    GFD265731Courtesy of FORD MOTOR COMPANY
  108. Connect the wiring harness electrical connectors and attach the retainers.
    GFD265732Courtesy of FORD MOTOR COMPANY
  109. Install the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer
    GFD265733Courtesy of FORD MOTOR COMPANY
  110. Inspect and install new intake manifold gaskets if necessary.
    GFD265734Courtesy of FORD MOTOR COMPANY
  111. 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.

    Finger tight.

    GFD265735Courtesy of FORD MOTOR COMPANY
  112. Tighten the intake manifold bolts.

    Torque

    : 177 lb.in (20 Nm)

    GFD265736Courtesy of FORD MOTOR COMPANY
  113. Install the vapor tube. Refer to: Quick Release Coupling .
    GFD265737Courtesy of FORD MOTOR COMPANY
  114. NOTE: Install a new gasket.

    Install the thermostat housing and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265738Courtesy of FORD MOTOR COMPANY
  115. NOTE: Install the generator stud before the generator is installed.

    • Tighten the generator stud to:

      Torque

      : 71 lb.in (8 Nm)

    • Tighten the nut and 2 bolts to:

      Torque

      : 18 lb.ft (25 Nm)

    GFD265739Courtesy of FORD MOTOR COMPANY
  116. Install the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer
    GFD265740Courtesy of FORD MOTOR COMPANY
  117. Install the A/C compressor and the fasteners.

    Torque

    : 18 lb.ft (25 Nm)

    GFD265741Courtesy of FORD MOTOR COMPANY
  118. NOTE: Install a new O-ring seal.

    Install the coolant pump and the bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD265742Courtesy of FORD MOTOR COMPANY
  119. Finger tight.
    GFD265743Courtesy of FORD MOTOR COMPANY
  120. Install the belt tensioner and the bolts.

    Torque

    : 18 lb.ft (25 Nm)

    GFD265744Courtesy of FORD MOTOR COMPANY
  121. NOTE: Under no circumstances should the A/C compressor belt, accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the A/C compressor belt, accessory drive belt or pulleys.

    Install the accessory drive belt.

    GFD265745Courtesy of FORD MOTOR COMPANY
  122. Tighten.

    Torque

    : 177 lb.in (20 Nm)

    GFD265746Courtesy of FORD MOTOR COMPANY
  123. NOTE: After installation, make sure the A/C compressor belt is correctly seated on the crankshaft and the A/C compressor pulleys.

    Position the A/C compressor belt onto the A/C compressor pulley and around the special tool on the crankshaft pulley. Make sure that the belt is engaged with the crankshaft pulley and rotate the crankshaft clockwise to install the A/C compressor belt. Use Special Service Tool: 303-1252 Stretchy Belt Remover/ Installer Tool.

    GFD265747Courtesy of FORD MOTOR COMPANY
  124. Connect the wiring harness electrical connector and attach the retainers.
    GFD265748Courtesy of FORD MOTOR COMPANY
  125. Connect the wiring harness electrical connector.
    GFD265749Courtesy of FORD MOTOR COMPANY
  126. Connect the wiring harness electrical connector.
    GFD265750Courtesy of FORD MOTOR COMPANY
  127. Connect the wiring harness electrical connectors and attach the retainers.
    GFD265751Courtesy of FORD MOTOR COMPANY
  128. Install the B+ cable and the nut.

    Torque

    : 150 lb.in (17 Nm)

    GFD265752Courtesy of FORD MOTOR COMPANY
  129. Connect the wiring harness electrical connectors and attach the retainers.
    GFD265753Courtesy of FORD MOTOR COMPANY
  130. Connect the wiring harness electrical connectors and attach the retainers.
    GFD265754Courtesy of FORD MOTOR COMPANY
  131. Install the ground strap and the bolt.

    Torque

    : 89 lb.in (10 Nm)

    GFD265755Courtesy of FORD MOTOR COMPANY
  132. Connect the wiring harness electrical connectors.
    GFD265756Courtesy of FORD MOTOR COMPANY
  133. Connect the wiring harness electrical connector and attach the retainers.
    GFD265757Courtesy of FORD MOTOR COMPANY
  134. Connect the wiring harness electrical connectors and attach the retainers.
    GFD265758Courtesy of FORD MOTOR COMPANY
  135. Connect the wiring harness electrical connectors and attach the retainers.
    GFD265759Courtesy of FORD MOTOR COMPANY
  136. Install the PCV tube. Refer to: Quick Release Coupling .
    GFD265760Courtesy of FORD MOTOR COMPANY
  137. Remove the engine from the engine stand.
  138. NOTE: Special bolts are used for installation. Do not use standard bolts.

    If equipped with a automatic transmission. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

    Torque

    :Stage 1: 37 lb.ft (50 Nm) Stage 2: 59 lb.ft (80 Nm) Stage 3: 83 lb.ft (112 Nm)

    GFD265761Courtesy of FORD MOTOR COMPANY
  139. NOTE: Special bolts are used for installation. Do not use standard bolts.

    If equipped with a manual transmission. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

    Torque

    :Stage 1: 37 lb.ft (50 Nm) Stage 2: 59 lb.ft (80 Nm) Stage 3: 83 lb.ft (112 Nm)

    GFD265762Courtesy of FORD MOTOR COMPANY
  140. NOTE: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
    NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol-based solvent so surfaces are free from oil film. Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in solvent.

    Position the clutch disc on the clutch pressure plate. Using a clutch aligner, centralize the clutch disc to the clutch pressure plate.

    GFD265763Courtesy of FORD MOTOR COMPANY
  141. NOTE: Install new bolts.

    Using a clutch aligner, position the clutch disc and clutch pressure plate on the flywheel.

    Torque

    : 21 lb.ft (29 Nm)

GFD265764Courtesy of FORD MOTOR COMPANY
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