Engine - Lower End

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Exploded View Of Engine Components (Lower End)

Courtesy of FORD MOTOR CO.

ITEM DESCRIPTION

Item	Part Number	Description
1	6010	Cylinder block
2	W500225	Knock Sensor (KS) bolt (2 required)
3	12A699	KS (2 required)
4	6211	Upper connecting rod bearing (8 required)
5	6135	Piston pin (8 required)
6	6159	Outer oil control ring (8 required)
7	6161	Inner oil control ring (8 required)
8	6150	Upper compression ring (8 required)
9	6152	Lower compression ring (8 required)
10	6159	Outer oil control ring (8 required)
11	6140	Piston pin retainer (16 required)
12	6110	Piston (8 required)
13	6200	Connecting rod assembly (8 required)
14	6K318	Crankshaft rear seal retainer plate
15	6375	Flexplate (automatic transmission)
16	N806168	Flexplate bolt (automatic transmission) (8 required)
17	N808139	Flywheel bolt (manual transmission) (8 required)
18	6375	Flywheel (manual transmission)
19	7120	Pilot bearing
20	6310	Crankshaft oil slinger
21	6701	Crankshaft rear seal
22	N806155	Crankshaft rear seal retainer plate bolt (6 required)
23	6714	Oil filter
24	6A642	Oil cooler
25	N620482	Oil filter adapter nut
26	6881	Oil filter adapter
27	W712913	Oil filter adapter stud
28	9278	Engine Oil Pressure (EOP) switch
29	N806156	Oil filter adapter bolt (4 required)
30	6A636	Oil filter adapter gasket
31	W701605	Oil pan bolt (16 required)
32	6675	Oil pan
33	6710	Oil pan gasket
34	N605904	Oil pump screen and pickup tube bolt
35	N806155	Oil pump screen and pickup tube bolt (2 required)
36	6622	Oil pump screen and pickup tube
37	N806180	Oil pump screen and pickup tube spacer
38	6345	Crankshaft main bearing cap bolt (9 required)
39	6K258	Crankshaft main bearing cap stud
40	6A346	Crankshaft main bearing dowel (10 required)
41	6325	Crankshaft main bearing cap (5 required)
42	6K302	Crankshaft thrust washer - lower
43	6A338	Crankshaft bearing - lower (5 required)
44	6303	Crankshaft
45	N806201	Crankshaft key
46	6W337	Crankshaft bearing - upper
47	6A341	Crankshaft thrust washer - upper (2 required)
48	6333	Crankshaft bearing - upper (4 required)
49	-	Connecting rod bearing cap (part of 6200) (8 required)
50	6211	Connecting rod bearing (8 required)
51	6621	Oil pump
52	N806183	Oil pump bolt (3 required)
53	6C357	Crankshaft main bearing cap side bolts (10 required)

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

Fig 2: Locating Main Bearing Code Found On Front Of Engine Block
Courtesy of FORD MOTOR CO.
Record the main bearing code found on the back of the crankshaft.

Fig 3: Locating 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 No. 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 4: 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 5: Bearing Select Fit Chart (Oversize 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 in illustration for location purposes only. Do not install the upper thrust washers until the crankshaft is installed. Refer to the following 2 steps.

Fig 6: 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 7: Installing Rear Crankshaft Upper Thrust Washer At No. 5 Main Boss

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 8: Installing Front Crankshaft Upper Thrust Washer At Front Of No. 5 Main Boss

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 9: Installing Lower Crankshaft Thrust Washer To No. 5 Main Bearing Cap

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 10 dowel pins so the flat sides face the crankshaft.

Fig 10: Locating Crankshaft Lower Main Bearings
Courtesy of FORD MOTOR CO.
Install the 10 vertical main bearing cap fasteners and tighten in 2 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 11: Identifying Vertical Main Bearing Cap Fasteners In Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the 10 side bolts and tighten them in 2 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 12: Identifying Bolts In Tightening Sequence
  Courtesy of FORD MOTOR CO.
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 13: Identifying Ring Gaps
Courtesy of FORD MOTOR CO.
Make sure the dimple in the piston faces the front of the engine.

Fig 14: Locating Dimple In Piston Faces
Courtesy of FORD MOTOR CO.

NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

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 in illustration.

Using the Piston Ring Compressor and the Connecting Rod Installer, 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 15: Lubricating Rod Bearings
  Courtesy of FORD MOTOR CO.

NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

Fig 16: Removing Connecting Rod Installer

Courtesy of FORD MOTOR CO.

Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.

NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

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 16 new bolts loosely.

NOTE: Main bearing caps are removed for clarity.

Tighten the 16 bolts in 2 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 43 Nm (32 lb-ft).
- Stage 2: Tighten an additional 105 degrees.
  
  Fig 17: Identifying Connecting Rod Bearing Caps Tighten 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 .
Position the oil pump and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 18: Locating Oil Pump And Bolts
  Courtesy of FORD MOTOR CO.
Install the oil pump screen and pickup tube spacer.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 19: Locating Oil Pump Screen And Pickup Tube Spacer
  Courtesy of FORD MOTOR CO.

NOTE: 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 3 bolts.
- Tighten the 2 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 20: Locating Oil Pump Screen And Pickup Tube And Bolts
  Courtesy of FORD MOTOR CO.
Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.

Fig 21: Positioning Crankshaft With Crankshaft Holding Tool
Courtesy of FORD MOTOR CO.

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

NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry or engine damage may occur.

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

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

NOTE: LH shown in illustration, RH similar.

Fig 22: Locating Cylinder Head Gaskets And Cylinder Heads And Dowels

Courtesy of FORD MOTOR CO.

Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 cylinder head bolts loosely.

NOTE: RH shown in illustration, LH similar.

Tighten the 20 bolts in 3 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 23: Identifying Cylinder Head Bolts Tighten Sequence
  Courtesy of FORD MOTOR CO.
Remove the Cylinder Head Remover/Installer from the LH cylinder head.

Fig 24: Removing Cylinder Head Remover/Installer From LH Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the Cylinder Head Remover/Installer from the RH cylinder head.

Fig 25: Removing Cylinder Head Remover/Installer From RH Cylinder Head
Courtesy of FORD MOTOR CO.
Install the 24 hydraulic lash adjusters into the RH and LH cylinder heads.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  
  Fig 26: Installing 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 in illustration, RH similar.

Install the 5 LH and 5 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 20 bolts loosely.
- Tighten to 10 Nm (89 lb-in) in the sequence shown in illustration.
  
  Fig 27: Identifying Camshaft Bearing Cap Bolt Loosening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: LH shown in illustration, RH similar.

Fig 28: Locating Camshaft Phaser And Sprocket Assembly Bolt

Courtesy of FORD MOTOR CO.

Install the camshaft phaser and sprockets and new camshaft phaser and sprocket bolts finger-tight.

NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket.

NOTE: LH shown in illustration, RH similar.

Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 29: Tightening LH Camshaft Phaser And Sprocket Assembly
  Courtesy of FORD MOTOR CO.

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

NOTE: 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 or engine damage may occur.

Fig 30: Compressing Tensioner Plunger Using Vise

Courtesy of FORD MOTOR CO.

Compress the tensioner plunger, using a vise.
Install the Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.

Fig 31: Installing 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 32: Locating Copper Link Timing Marks
Courtesy of FORD MOTOR CO.
Install the crankshaft sprocket, making sure the flange faces forward.

Fig 33: Locating Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Position the LH and RH timing chain guides and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 34: Locating 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 35: Aligning Crankshaft Sprocket Timing Mark And Timing Chain Link
Courtesy of FORD MOTOR CO.

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

Fig 36: Locating Timing Mark On Timing Chain

Courtesy of FORD MOTOR CO.

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

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 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 37: Locating LH Timing Chain Tensioner Bolts
  Courtesy of FORD MOTOR CO.
Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.

Fig 38: Removing Retaining Clip From LH 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 39: Aligning (Outer) Sprocket Timing Mark And 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.

Fig 40: Locating Upper Stabilizer Link Nut

Courtesy of FORD MOTOR CO.

Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is positioned between the 2 copper (marked) chain links.
Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 41: Locating RH Timing Chain Tensioner Bolts
  Courtesy of FORD MOTOR CO.
Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.

Fig 42: Removing Retaining Clip From LH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
As a post-check, verify correct alignment of all timing marks.

Fig 43: Locating Timing Chain Mark Location
Courtesy of FORD MOTOR CO.
Install the crankshaft sensor ring on the crankshaft.

Fig 44: Locating Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.

NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, install all of the camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.
  
  Fig 45: Installing Camshaft Roller Followers
  Courtesy of FORD MOTOR CO.

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. 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 may cause future oil leakage.

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

Fig 46: Locating Engine Front Cover Onto Dowels

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown in illustration.
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 47: Installing Engine Front Cover Gasket On Engine Front Cover
Courtesy of FORD MOTOR CO.

Tighten the 15 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).

ITEM DESCRIPTION

Item	Part Number	Description
1	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
2	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
3	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
4	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
5	N806177	Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
6	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
7	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
8	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
9	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
10	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
11	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
12	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94

Fig 48: Identifying Engine Front Cover Fasteners Tighten Sequence

Courtesy of FORD MOTOR CO.

NOTE: 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.

Using a new O-ring seal, 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 49: Identifying Coolant Pump
  Courtesy of FORD MOTOR CO.
Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 50: Locating Coolant Pump Bolts
  Courtesy of FORD MOTOR CO.
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 51: Lubricating Engine Front Cover And Crankshaft Seal Inner Lip With Clean Engine Oil
Courtesy of FORD MOTOR CO.
Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Crankshaft Front Oil Seal Installer, install a new crankshaft front seal.

Fig 52: Installing Crankshaft Front Seal Into Engine Front Cover 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 may cause future oil leakage.

Fig 53: Identifying 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.
Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

Fig 54: Installing Crankshaft Pulley Using Special Tool
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 55: Installing Crankshaft Pulley Bolt And Washer
  Courtesy of FORD MOTOR CO.
Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 56: 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 57: 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 the bolts to 25 Nm (18 lb-ft).
- Tighten the nut to 48 Nm (35 lb-ft).
  
  Fig 58: Locating Oil Filter Adapter, Gasket And Nuts
  Courtesy of FORD MOTOR CO.

NOTE: RH shown in illustration, LH similar.

Install 16 new exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 59: Locating Exhaust Manifold Studs
  Courtesy of FORD MOTOR CO.
Position a new gasket, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown in illustration.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 60: Identifying Bolt Loosening Sequence Of Exhaust Manifold
  Courtesy of FORD MOTOR CO.

NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.

NOTE: Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator damage.

NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

NOTE: Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

Position the LH engine support insulator bracket and install 3 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional minimum of 60 degrees.
  
  Fig 61: Locating LH Engine Support Insulator Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Position a new gasket, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown in illustration.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 62: Identifying Bolt Tightening Sequence Of Exhaust Manifold
  Courtesy of FORD MOTOR CO.

NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.

NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

NOTE: Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

Position the RH engine support insulator bracket, position the engine support insulator bracket and install 3 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional minimum of 60 degrees.
  
  Fig 63: Locating RH Engine Support Insulator Bracket Bolts
  Courtesy of FORD MOTOR CO.

NOTE: 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 64: 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.

NOTE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

Position the RH valve cover and gasket on the cylinder head and tighten the 9 fasteners in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 65: Identifying Cylinder Head Bolt Tighten Sequence
  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 66: 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.

NOTE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

Position the LH valve cover and gasket on the cylinder head and tighten the 10 fasteners in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 67: Identifying Cylinder Head Bolt Tighten Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Do not reuse the O-ring seals.

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

Fig 68: Sliding Coolant Tube Forward With O-ring 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 69: Identifying Coolant Tube Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the 2 Knock Sensor (KS) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 70: Identifying Knock Sensors (KS)
  Courtesy of FORD MOTOR CO.
Install the oil level indicator tube and the front bolt.
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 71: 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 72: Locating Rear Oil Level Indicator Tube Bolt
  Courtesy of FORD MOTOR CO.
Position the intake manifold vacuum tube support bracket and install the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 73: Locating Intake Manifold Vacuum Tube Support Bracket And Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

NOTE: LH shown in illustration, RH similar.

Install the 8 ignition coils and the 8 bolts.
- Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 74: Locating Ignition Coil Bolts
  Courtesy of FORD MOTOR CO.
Position the engine wiring harness onto the engine assembly.
Connect the engine wiring harness position retainers to the front of the LH valve cover and the LH CMP sensor electrical connector.

Fig 75: Locating Engine Wiring Harness Position Retainers
Courtesy of FORD MOTOR CO.
Connect the Engine Oil Pressure (EOP) switch electrical connector.

Fig 76: Locating Engine Oil Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Install the LH radio ignition interference capacitor and the nut.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 77: Identifying Radio Ignition Interference Capacitor And Stud Bolt
  Courtesy of FORD MOTOR CO.
Connect the Cylinder Head Temperature (CHT) sensor electrical connector.

Fig 78: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the RH VCT solenoid electrical connector.

Fig 79: Locating VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Install the RH radio ignition interference capacitor and the nut.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 80: Identifying Radio Ignition Interference Capacitor And Stud Bolt
  Courtesy of FORD MOTOR CO.
Connect the RH CMP sensor electrical connector.

Fig 81: Locating CMP Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the engine wiring harness position retainers to the front of the RH valve cover.

Fig 82: Locating RH Valve Cover
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
Courtesy of FORD MOTOR CO.

NOTE: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged.

NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to remove it.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the engine cooling fan onto the cooling pump pulley.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 84: Removing Cooling Fan And Clutch Assembly
  Courtesy of FORD MOTOR CO.
Install the Engine Lifting Bracket.

Fig 85: Identifying Modular Engine Lift Bracket (303-F047)
Courtesy of FORD MOTOR CO.
Using a suitable floor crane, remove the engine from the engine stand.

NOTE: 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. Failure to follow this procedure can cause future oil leakage.

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 86: Applying Bead Of Crankshaft Rear Seal Retainer Plate

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 87: Locating Crankshaft Rear Seal Retainer Plate And Bolts
Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 88: Identifying Bolts In Tightening Sequence
  Courtesy of FORD MOTOR CO.

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. 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 89: Locating Crankshaft Rear Seal Retainer Plate-To-Cylinder Block Sealing Surface

Courtesy of FORD MOTOR CO.

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

Fig 90: 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 16 bolts.

Fig 91: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Tighten the 16 bolts in 3 stages, in the sequence shown in illustration.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
  
  Fig 92: Identifying Oil Pan Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.

Fig 93: Installing Crankshaft Rear Oil Seal Using Special Tools

Courtesy of FORD MOTOR CO.

Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.

NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation.

Fig 94: Installing Crankshaft Rear Oil Slinger Using Special Tools

Courtesy of FORD MOTOR CO.

Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger.
Install the flexplate or flywheel and the 8 bolts in the sequence shown in illustration.
- Tighten to 80 Nm (59 lb-ft).
  
  Fig 95: Identifying Flexplate Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.