Section 6 (Engine - 3.0L (4V)): Assembly: Engine

WARNING: This page is about a different variant/trim than selected.

Special Tools

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Piston Ring Compressor	303-D032 (D81L-6002-C)
Courtesy of FORD MOTOR CO.	Dial Indicator Gauge with Holding Fixture	100-002 (TOOL-4201-C)
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket Set	303-1140
Courtesy of FORD MOTOR CO.	Installer, Camshaft Oil Seal	303-464 (T94P-6256-BH)
Courtesy of FORD MOTOR CO.	Installer, Camshaft Pulley	303-458 (T94P-6312-AH3), part of 303-S455
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Main Oil Seal	303-178 (T82L-6701-A)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Vibration Damper	303-102 (T74P-6316-B)
Courtesy of FORD MOTOR CO.	Installer, Front Cover Oil Seal	303-335 (T88T-6701-A)
Courtesy of FORD MOTOR CO.	Installer, Power Steering Pump Pulley	211-185 (T91P-3A733-A)
Courtesy of FORD MOTOR CO.	Installer Bolts, Crankshaft Rear Main Oil Seal	303-384 (T91P-6701-A)
Courtesy of FORD MOTOR CO.	Lifting Brackets, Engine	134-00243 or equivalent
Courtesy of FORD MOTOR CO.	Lifting Brackets, Engine	303-050 (T70P-6000)
Courtesy of FORD MOTOR CO.	Protector, Camshaft Oil Seal	303-463 (T91P-6256-AH)
Courtesy of FORD MOTOR CO.	Spacer, Water Pump Pulley	303-459 (T94P-6312-AH4), part of 303-S455
Courtesy of FORD MOTOR CO.	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Strap Wrench	303-D055 (D85L-6000-A)
Courtesy of FORD MOTOR CO.	Universal Adapter Brackets	014-0001

Material

Item	Specification
Motorcraft Metal Surface Prep ZC-31-A	-
Motorcraft Premium Gold Engine Coolant with Bittering Agent (bittered in US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)	WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent	WSS-M2C930-A
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Thread Sealant with PTFE TA-24	WSK-M2G350-A2

Fig 1: Exploded View Of Lower Engine Block (1 Of 2)

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	12A227	Ignition pulse wheel
2	6L266	RH timing chain tensioner
3	6K255	RH timing chain tensioner arm
4	6268	RH timing chain
5	6M280	Oil control valve
6	6C260	RH Variable Camshaft Timing (VCT) assembly
7	6306	Crankshaft sprocket
8	6L266	LH timing chain tensioner
9	6K255	LH timing chain tensioner arm
10	6268	LH timing chain
11	6C261	LH VCT assembly
12	6621	Oil pump
13	6B752	Oil separator gasket
14	6869	Cover
15	6701	Crankshaft rear oil seal
16	6A373	Spacer plate
17	6K375	Flexplate
18	9278	Oil pressure switch
19	19N586	A/C compressor bracket
20	W705934	Woodruff key
21	6622	Oil pickup tube and screen
22	6687	Oil pan baffle
23	6890	Oil filter adapter
24	6714	Oil filter
25	6675	Oil pan
26	10300	Generator
27	6B209	Accessory drive belt tensioner
28	6700	Crankshaft front seal
29	6316	Crankshaft pulley
30	N806165	Crankshaft pulley washer
31	W701512	Crankshaft pulley bolt
32	19A216	Accessory drive belt idler (non-grooved)
33	6C315	Crankshaft Position (CKP) sensor
34	6B288	Camshaft Position (CMP) sensor
35	19A216	Accessory drive belt idler pulley (grooved)
36	6B288	CMP sensor
37	6019	Front cover

Fig 2: Exploded View Of Lower Engine Block (2 Of 2)

Courtesy of FORD MOTOR CO.

ITEM DESCRIPTION TABLE

Item	Part Number	Description
1	6150	Piston compression upper ring (6 required)
2	6152	Piston compression lower ring (6 required)
3	6159	Piston oil control upper segment ring (6 required)
4	6161	Piston oil control spacer (6 required)
5	6159	Piston oil control lower segment ring (6 required)
6	6140	Piston pin retainer (12 required)
7	6135	Piston pin (6 required)
8	6110	Piston (6 required)
9	6200	Connecting rod (6 required)
10	6211	Connecting rod upper bearing (6 required)
11	6211	Connecting rod lower bearing (6 required)
12	6210	Connecting rod cap (6 required)
13	6010	Cylinder block
14	6333	Cylinder block crankshaft main bearing (4 required)
15	6A341	Crankshaft upper thrust bearing
16	6303	Crankshaft
17	6333	Lower cylinder block crankshaft main bearings (3 required)
18	6337	Lower cylinder block crankshaft main thrust bearing
19	6F095	Lower cylinder block

Fig 3: Exploded View Of Upper Engine Components

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6582	RH valve cover
2	9F479	Mass Air Flow (MAF) sensor
3	9424	Upper intake manifold
4	9F991	Throttle Body (TB)
5	12A375	Coil-on-plug (6 required)
6	6A505	LH valve cover
7	9F792	Fuel rail
8	9F543	Fuel injector (6 required)
9	9K461	Lower intake manifold
10	6B280	Camshaft thrust bearing cap
11	6B280	Camshaft bearing cap
12	6C524	Variable Camshaft Timing (VCT) actuator
13	6A267	LH intake camshaft
14	6A269	LH exhaust camshaft
15	6B295	Camshaft oil seal retainer gasket
16	6B293	Camshaft oil seal retainer
17	-	Camshaft oil seal
18	6A359	Coolant pump drive pulley
19	6050	LH cylinder head
20	12405	Spark plug
21	6C501	Hydraulic lash adjuster
22	6513	Valve spring
23	6529	Camshaft roller follower
24	8501	Coolant pump
25	8K543	Coolant pump belt
26	6518	Valve spring retainer key
27	6514	Valve spring retainer
28	6A517	Valve stem seal
29	-	Oil level indicator
30	6754	Oil level indicator tube
31	6083	LH cylinder head gasket
32	6507	Intake valve
33	6505	Exhaust valve
34	6051	RH cylinder head gasket
35	8548	Coolant bypass tube
36	6050	RH cylinder head
37	6C254	VCT actuator
38	6A266	RH intake camshaft
39	6A268	RH exhaust camshaft
40	6B280	Camshaft thrust bearing cap
41	6A258	Camshaft bearing cap

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

NOTE: If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

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. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Select the crankshaft main bearings for each crankshaft journal.
1. Read the code on the crankshaft flange.
2. Read the code on the cylinder block rear face.
  - The first 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for main No. 2.
  - The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2 numbers for main No. 4.
  Fig 4: Identifying Crankshaft Flange & Cylinder Block Rear Face
  Courtesy of FORD MOTOR CO.
NOTE: This procedure is for selecting bearings using a new crankshaft.
Using the table below, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
- For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
Fig 5: Bearing Selection Table
Courtesy of FORD MOTOR CO.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
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.

Fig 6: Locating Crankshaft Main Bearings Installation Position
Courtesy of FORD MOTOR CO.
Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the lower cylinder block.

Fig 7: Locating Main Bearings Installation Position
Courtesy of FORD MOTOR CO.
Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.

Fig 8: Locating Crankshaft Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the crankshaft key.

Fig 9: Locating Crankshaft Key
Courtesy of FORD MOTOR CO.
Apply clean engine oil to the crankshaft main and rod bearing journals.
Position the crankshaft in the cylinder block.

Fig 10: Locating Crankshaft In Cylinder Block
Courtesy of FORD MOTOR CO.
Apply gasket and sealant to the cylinder block as shown below.
NOTE: The lower cylinder block must be installed and the bolts tightened within 4 minutes of applying the sealant.

NOTE: Clean and degrease both surfaces using metal surface prep before applying sealant.

Fig 11: Applying Gasket & Sealant To Cylinder Block
Courtesy of FORD MOTOR CO.
Position the lower cylinder block and install the new bolts and new studs.
- Tighten the bolts and studs in the sequence shown in 4 stages.
- Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft).
- Stage 2: Tighten fasteners 9 through 16 to 40 Nm (30 lb-ft).
- Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees.
- Stage 4: Tighten fasteners 17 through 22 to 25 Nm (18 lb-ft).
NOTE: Fasteners No. 5 through 8 are studs. Fasteners No. 18 through 22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 1 through 4, 17 are M8 x 1.25 mm x 96 mm (0.05 in x 3.75 in) bolts. Fasteners 9 through 12 are M10 x 1.5 mm x 106.8 mm (0.06 in x 4.20 in)/M8 x 1.25 mm x 21.5 mm (0.05 in x 0.84 in) studs. Fasteners 13 through 16 are M10 x 1.5 mm x 106.5 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position or engine damage can result.

Fig 12: Identifying Lower Cylinder Block Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
- 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 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
Fig 13: Measuring Crankshaft End Play
Courtesy of FORD MOTOR CO.
Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal.

Fig 14: Installing Crankshaft Rear Oil Seal
Courtesy of FORD MOTOR CO.
Install the engine-to-transaxle separator plate.

Fig 15: Locating Engine-To-Transaxle Separator Plate
Courtesy of FORD MOTOR CO.
Position the flexplate and install the bolts.
- Tighten to 80 Nm (59 lb-ft).
Fig 16: Locating Flexplate Bolts
Courtesy of FORD MOTOR CO.
Mount the engine on an engine stand.
Using the table, select the correct piston grade size for the cylinder bores.
- Measure the cylinder block bore diameter.
- Mark the outside of the block with the appropriate number(s) to identify bore grade size.
- Choose the correct piston grade size for the cylinder bore.
Fig 17: Cylinder Block Bore Diameter Table
Courtesy of FORD MOTOR CO.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.

NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to .

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

NOTE: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.

Fig 18: Locating Lower Rear Fender Bolts
Courtesy of FORD MOTOR CO.
Install the connecting rod caps and the new bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 23 Nm (17 lb-ft).
- Stage 2: Tighten to 43 Nm (32 lb-ft).
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

Fig 19: Locating Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
Install the oil separator cover, a new gasket and the bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 20: Locating Oil Separator Cover Bolts

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Position the new gaskets and the LH and RH cylinder heads. Install new bolts and tighten in the sequence shown in 6 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten to 90 Nm (66 lb-ft).
- Stage 3: Loosen one full turn.
- Stage 4: Tighten to 40 Nm (30 lb-ft).
- Stage 5: Tighten 90 degrees.
- Stage 6: Tighten 90 degrees.

Fig 21: Identifying Tightening Sequence Of Cylinder Head Bolts

Courtesy of FORD MOTOR CO.

Position the oil pump and install the 4 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 22: Identifying Tightening Sequence Of Oil Pump Bolts

Courtesy of FORD MOTOR CO.

If removed, install the crankshaft key into the keyway on the crankshaft.

Fig 23: Locating Crankshaft Key

Courtesy of FORD MOTOR CO.

Install the crankshaft pulley bolt and washer and rotate the crankshaft keyway to the 11 o'clock position to locate Top Dead Center (TDC).

Fig 24: Locating Crankshaft Damper Bolt

Courtesy of FORD MOTOR CO.

Apply clean engine oil to the LH and RH camshaft roller followers.

NOTE: The camshaft roller followers must be installed in their original positions or damage to the engine may occur.

NOTE: RH shown, LH similar.

Install the LH and RH camshaft roller followers.

Fig 25: Locating Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Position the Variable Camshaft Timing (VCT) actuators onto the intake camshafts.
- Install the bolts finger-tight.

Fig 26: Locating VCT Actuator Onto Intake Camshaft

Courtesy of FORD MOTOR CO.

Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
- Align the RH camshafts as shown.

Fig 27: Locating RH Camshafts Position

Courtesy of FORD MOTOR CO.

NOTE: The camshaft caps must be installed in their original positions or damage to the engine may occur.

NOTE: Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed or damage to the thrust caps may occur.

NOTE: Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil.

Install the RH camshaft bearing caps.
- Loosely install the bolts.

Fig 28: Locating Camshaft Bearing Caps

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil.

Install the RH camshaft bearing thrust caps.
- Loosely install the bolts.

Fig 29: Locating Camshaft Bearing Thrust Caps

Courtesy of FORD MOTOR CO.

Tighten the RH camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).

Fig 30: Tightening RH Camshaft Bearing Cap Bolts In Sequence

Courtesy of FORD MOTOR CO.

NOTE: Do not allow the camshaft to rotate from the neutral position while removing the Variable Camshaft Timing (VCT) actuator or damage to the engine may occur.

NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the VCT actuator bolt.

Tighten the RH VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.

Fig 31: Locating VCT Actuator And Bolt

Courtesy of FORD MOTOR CO.

Lubricate the LH camshafts with clean engine oil and carefully position the camshafts into the cylinder head.
- Align the LH camshafts as shown.

Fig 32: Locating Camshafts In Neutral Position

Courtesy of FORD MOTOR CO.

NOTE: The camshaft caps must be installed in their original positions or damage to the engine may occur.

NOTE: Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed or damage to the thrust caps may occur.

NOTE: Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil.

Install the LH camshaft bearing caps.
- Loosely install the bolts.

Fig 33: Loosely Installing Bolts

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil.

Install the LH camshaft bearing thrust caps.
- Loosely install the bolts.

Fig 34: Loosely Installing Bolts

Courtesy of FORD MOTOR CO.

Tighten the LH camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).

Fig 35: Tightening LH Camshaft Bearing Cap Bolts In Sequence

Courtesy of FORD MOTOR CO.

NOTE: Do not allow the camshaft to rotate from the neutral position while tightening the Variable Camshaft Timing (VCT) actuator bolt or damage to the engine may occur.

NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the VCT actuator bolt.

Tighten the LH VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.

Fig 36: Locating VCT Actuator And Bolt

Courtesy of FORD MOTOR CO.

NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.

Install the camshaft oil seal retainer and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 37: Locating Camshaft Oil Seal Retainer And Bolts

Courtesy of FORD MOTOR CO.

NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.

Using the Camshaft Oil Seal Protector, Camshaft Oil Seal Installer and the Power Steering Pump Pulley Installer, install a new camshaft oil seal.

Fig 38: Identifying Special Tools (303-463, 303-464 And 211-185)

Courtesy of FORD MOTOR CO.

Remove the crankshaft pulley bolt and washer.

Fig 39: Locating Crankshaft Damper Bolt

Courtesy of FORD MOTOR CO.

Install the crankshaft sprockets with the timing marks out.

Fig 40: Locating Timing Marks On Crankshaft Sprockets

Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Position the chain tensioner in a soft-jawed vise.

Fig 41: Identifying Chain Tensioner In Soft-Jawed Vise

Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

Fig 42: Holding Chain Tensioner Ratchet Lock Mechanism Away From Ratchet Stem

Courtesy of FORD MOTOR CO.

NOTE: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Slowly compress the timing chain tensioner.
Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip.

Fig 43: Retaining Tensioner Piston With 1.5-mm (0.06-in) Wire Or Paper Clip

Courtesy of FORD MOTOR CO.

If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
1. Mark any link to use as the crankshaft timing mark.
2. Starting with the crankshaft timing mark, count counterclockwise 29 links and mark the link.
3. Continue counting counterclockwise to link 42 and mark the link.

Fig 44: Locating Crankshaft & Camshaft Timing Marks On LH & RH Timing Chains

Courtesy of FORD MOTOR CO.

Verify that the LH camshafts are correctly positioned.

Fig 45: Locating Camshafts In Neutral Position

Courtesy of FORD MOTOR CO.

Install the VCT assembly and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 46: Identifying LH VCT Assembly Bolts

Courtesy of FORD MOTOR CO.

Install the LH timing chain.
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.

Fig 47: Aligning Marks On Timing Chain With Marks On Camshaft And Crankshaft Sprockets

Courtesy of FORD MOTOR CO.

Install the LH timing chain tensioner arm and the LH timing chain tensioner.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the 2 bolts.
4. Tighten to 25 Nm (18 lb-ft).

Fig 48: Identifying Timing Chain Tensioner Arm & Bolts

Courtesy of FORD MOTOR CO.

Install the crankshaft pulley bolt and washer and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.

Fig 49: Locating Crankshaft Keyway

Courtesy of FORD MOTOR CO.

Verify that the RH camshafts are correctly positioned.

Fig 50: Locating RH Camshafts Position

Courtesy of FORD MOTOR CO.

Install the RH VCT assembly and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 51: Locating RH VCT Assembly Bolts

Courtesy of FORD MOTOR CO.

Install the RH timing chain.
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.

Fig 52: Aligning Marks On Timing Chain With Marks On Camshaft And Crankshaft Sprockets

Courtesy of FORD MOTOR CO.

Install the RH timing chain tensioner and tensioner arm.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the 2 bolts.
4. Tighten to 25 Nm (18 lb-ft).

Fig 53: Identifying Tensioner Arm, Tensioner And Bolts

Courtesy of FORD MOTOR CO.

Remove the LH and RH timing chain tensioner piston retaining wires.
Rotate the crankshaft counterclockwise 120 degrees to TDC.

NOTE: Failure to verify correct timing drive component alignment will result in severe engine damage.

Verify the timing with the following steps.
1. There should be 12 chain links between the camshaft timing marks.
2. There should be 27 chain links between the camshaft and the crankshaft timing marks.
3. There should be 30 chain links between the camshaft and the crankshaft timing marks.

Fig 54: Locating Align Marks On Chain

Courtesy of FORD MOTOR CO.

Remove the crankshaft pulley bolt and washer.

Fig 55: Identifying Damper Bolt

Courtesy of FORD MOTOR CO.

NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 30RFF only (orange in color).

Install the ignition pulse wheel.

Fig 56: Identifying Ignition Pulse Wheel

Courtesy of FORD MOTOR CO.

Install 3 new gaskets in the front cover.

NOTE: Clean the sealing surfaces with metal surface prep before applying gasket and sealant.

NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.

Apply a 6 mm (0.23 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.

Fig 57: Locating Silicone Gasket And Sealant On Cylinder Block

Courtesy of FORD MOTOR CO.

NOTE: Fasteners 1 and 13 are stud bolts.

Position the engine front cover and install the 14 bolts and 2 stud bolts.
- Tighten in the sequence shown to 25 Nm (18 lb-ft).

Fig 58: Locating Tighten Sequence Of Engine Front Cover Bolts

Courtesy of FORD MOTOR CO.

Apply clean engine oil to the seal lip and seal bore before installing the seal.
Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.

Fig 59: Installing Crankshaft Seal Using Special Tools (303-335 And 303-102)

Courtesy of FORD MOTOR CO.

NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant.

NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of applying the silicone gasket and sealer.

Apply silicone gasket and sealant to the end of the keyway slot.

Fig 60: Applying Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

Fig 61: Installing Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Install the bolt and washer. Using the Strap Wrench to hold the crankshaft pulley, tighten the bolt in 4 stages:
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.

Fig 62: Identifying Special Tool (303-D055) And Crankshaft Pulley Bolts

Courtesy of FORD MOTOR CO.

Install the accessory drive belt tensioner and the 2 idler pulleys.
- Tighten the tensioner bolt to 45 Nm (33 lb-ft).
- Tighten the idler pulley bolts to 25 Nm (18 lb-ft).

Fig 63: Locating Accessory Drive Belt Tensioner And Idler Pulleys

Courtesy of FORD MOTOR CO.

Install the oil pan baffle and the 8 nuts.
- Tighten the oil pan baffle nuts in 2 stages.
  - Stage 1: Tighten the 4 smaller nuts to 5 Nm (44 lb-in) and the larger nuts to 15 Nm (133 lb-in).
  - Stage 2: Tighten all 8 nuts an additional 45 degrees.

Fig 64: Locating Oil Pan Baffle Nuts

Courtesy of FORD MOTOR CO.

Install a new O-ring seal on the oil pump screen and pickup tube.
- Lubricate with clean engine oil.

Fig 65: Locating O-Ring Seal

Courtesy of FORD MOTOR CO.

Install the oil pump screen and pickup tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 66: Locating Oil Pump Screen & Pickup Tube Bolts

Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.

Install the LH and RH spark plugs.
- Tighten to 15 Nm (133 lb-in).

Fig 67: Locating Spark Plugs

Courtesy of FORD MOTOR CO.

Install the new gasket in the LH valve cover in the following sequence.
1. Install the gasket at waffle pads and then the corners.
2. Install the gasket around bolt holes.
3. Install the remaining part of the gasket.
  
  Fig 68: Identifying LH Valve Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.

Apply a an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints and the cam seal retainer-to-cylinder head joints.

Fig 69: Locating Silicone Gasket Sealant

Courtesy of FORD MOTOR CO.

Position the LH valve cover and install the bolts and stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 70: Identifying Tightening Sequence Of Valve Cover Bolts

Courtesy of FORD MOTOR CO.

NOTE: Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

Install the 3 LH coil-on-plug assemblies and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).

Fig 71: Locating LH Coil-On-Plug Assemblies And Bolts

Courtesy of FORD MOTOR CO.

Install the new gasket in the RH valve cover in the following sequence.
- Install the gasket at waffle pads and then the corners.
- Install the gasket around bolt holes.
- Install the remaining part of the gasket.
  
  Fig 72: RH Valve Cover Gasket
  Courtesy of FORD MOTOR CO.

NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.

NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.

Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.

Fig 73: Locating Silicone Gasket Sealant

Courtesy of FORD MOTOR CO.

Position the RH valve cover and install the bolts and stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 74: Identifying Tightening Sequence Of Valve Cover Bolts

Courtesy of FORD MOTOR CO.

NOTE: Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

Install the 3 RH coil-on-plug assemblies and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).

Fig 75: Locating RH Coil-On-Plug Assemblies And Bolts

Courtesy of FORD MOTOR CO.

If equipped, install the block heater.
- Tighten to 40 Nm (30 lb-ft).

Fig 76: Locating Block Heater

Courtesy of FORD MOTOR CO.

NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.

Install the EOP switch.
- Tighten to 14 Nm (124 lb-in).

Fig 77: Locating EOP Switch

Courtesy of FORD MOTOR CO.

Install the KS and the bolt.
- Tighten to 20 Nm (177 lb-in).

Fig 78: Locating Knock Sensor (KS) And Bolt

Courtesy of FORD MOTOR CO.

Install the coolant pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in) then rotate 90 degrees.

Fig 79: Locating Coolant Pump And Bolts

Courtesy of FORD MOTOR CO.

NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

Install the Camshaft Pulley Installer on the camshaft as shown in the illustration.
- Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.

Fig 80: Installing Special Tool On Camshaft

Courtesy of FORD MOTOR CO.

NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.

NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on the Camshaft Pulley Installer (303-458).

Position the coolant pump pulley over the previously installed Camshaft Pulley Installer, Water Pump Pulley Spacer and the Power Steering Pump Pulley Installer, and on the end of the camshaft. Install the Camshaft Pulley Installer, Water Pump Pulley Spacer and the Power Steering Pump Pulley Installer, as shown in the illustration.
- Using the Camshaft Pulley Installer, Water Pump Pulley Spacer and the Power Steering Pump Pulley Installer, install the coolant pump pulley flush with the end of the camshaft.

Fig 81: Installing Coolant Pump Pulley Using Special Tools (211-185, 303-458, 303-459)

Courtesy of FORD MOTOR CO.

Install the coolant pump belt on the coolant pump pulley and position it on the coolant pump drive pulley.

Fig 82: Locating Coolant Pump Belt On Coolant Pump Pulley

Courtesy of FORD MOTOR CO.

NOTE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or pulley while installing the belt.

Rotate the crankshaft clockwise to seat the coolant pump belt on the coolant pump drive belt pulley.
Connect the coolant pump hose to the cylinder block outlet.

Fig 83: Locating Coolant Pump Hose From Cylinder Block Outlet

Courtesy of FORD MOTOR CO.

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

Install new O-ring seals, the coolant bypass tube, bolt and stud bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 84: Locating Bolt, Stud Bolt And Coolant Bypass

Courtesy of FORD MOTOR CO.

Install the thermostat housing.

Fig 85: Locating Clamps And Thermostat Housing

Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

Position the lower intake manifold and install the 8 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 86: Identifying Tightening Sequence Of Lower Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.

Fig 87: Locating O-Ring On Oil Level Indicator Tube

Courtesy of FORD MOTOR CO.

Position the oil level indicator and tube and install the stud bolt.
- Tighten to 9 Nm (80 lb-in).

Fig 88: Locating Oil Level Indicator Tube And Bolt

Courtesy of FORD MOTOR CO.

Install the LH catalytic converter bracket and the 2 bolts.
- Tighten to 35 Nm (26 lb-ft).

Fig 89: Locating LH Catalytic Converter Bracket Bolts

Courtesy of FORD MOTOR CO.

Install 6 new RH catalytic converter studs.
- Tighten to 12 Nm (106 lb-in).

Fig 90: Locating Exhaust Manifold Studs

Courtesy of FORD MOTOR CO.

All-Wheel Drive (AWD) engines

Install a new gasket, the RH exhaust manifold and 6 new nuts.
- Tighten to 20 Nm (177 lb-in) in the sequence shown.

Fig 91: Identifying Tightening Sequence Of RH Exhaust Manifold Nuts

Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) engines

Install a new gasket, the RH catalytic converter and 6 new nuts.
- Tighten to 20 Nm (177 lb-in) in the sequence shown.

Fig 92: Identifying Tightening Sequence Of RH Catalytic Converter Nuts

Courtesy of FORD MOTOR CO.

All engines

Install the A/C compressor bracket and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 93: Locating A/C Compressor Bracket Bolts

Courtesy of FORD MOTOR CO.

Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 94: Locating A/C Compressor Bolts

Courtesy of FORD MOTOR CO.

Install the generator and the 3 bolts.
- Tighten to 48 Nm (35 lb-ft).

Fig 95: Locating Generator Bolts

Courtesy of FORD MOTOR CO.

Position the wiring harness onto the engine.
Attach the wiring harness to the cylinder block.

Fig 96: Locating Wiring Harness From Cylinder Block

Courtesy of FORD MOTOR CO.

Install the wiring harness retainer bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 97: Identifying Wiring Harness Retainer Bolt

Courtesy of FORD MOTOR CO.

Position the power steering pump and reservoir assembly onto the engine and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 98: Locating Power Steering Pump Bolts

Courtesy of FORD MOTOR CO.

Install the 3 power steering reservoir nuts.
- Tighten to 9 Nm (80 lb-in).

Fig 99: Locating Power Steering Reservoir Nuts

Courtesy of FORD MOTOR CO.

Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.

Fig 100: Rotating Accessory Drive Belt Tensioner Counterclockwise

Courtesy of FORD MOTOR CO.

Attach the wiring harness retainer to the coolant bypass stud bolt.

Fig 101: Locating Wiring Harness Retainer

Courtesy of FORD MOTOR CO.

Position the wiring harness onto the engine and connect the ECT sensor electrical connector.

Fig 102: Locating Electronic Coolant Temperature Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the KS electrical connector.

Fig 103: Locating Knock Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the PCV valve electrical connector.

Fig 104: Locating Positive Crankcase Ventilation Valve Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the Power Steering Pressure (PSP) switch electrical connector.

Fig 105: Identifying Power Steering Pressure (PSP) Switch Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the Crankshaft Position (CKP) sensor electrical connector.

Fig 106: Identifying Crankshaft Position (CKP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Attach the 2 wiring harness retainers.

Fig 107: Identifying Wiring Harness Retainers

Courtesy of FORD MOTOR CO.

FWD engines

Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.

Fig 108: Identifying RH HO2S Electrical Connector

Courtesy of FORD MOTOR CO.

Attach the wiring harness retainer to the power steering stud bolt.

Fig 109: Locating Wiring Harness Retainer

Courtesy of FORD MOTOR CO.

Connect the RH catalyst monitor sensor electrical connector.

Fig 110: Identifying RH Catalyst Monitor Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

All engines

Install the radio frequency interference capacitor and the nut.
- Tighten to 6 Nm (53 lb-in).

Fig 111: Locating Radio Frequency Interference Capacitor And Nut

Courtesy of FORD MOTOR CO.

Connect the RH VCT solenoid and LH Camshaft Position (CMP) sensor electrical connectors.
- If equipped, attach the 2 wiring harness retainers to the valve cover stud bolts.

Fig 112: Locating RH VCT Solenoid And LH Camshaft Position Sensor Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the 3 RH coil-on-plug electrical connectors.
- Attach the 2 wiring harness pin-type retainers to the valve cover.

Fig 113: Locating RH Coil-On-Plug Electrical Connectors

Courtesy of FORD MOTOR CO.

NOTE: Only one wiring harness retainer shown, other wiring harness retainer similar.

Attach the 2 wiring harness retainers to the fuel rail.

Fig 114: Locating Fuel Rail Wiring Harness Retainer

Courtesy of FORD MOTOR CO.

Connect the 6 fuel injector electrical connectors (3 shown).

Fig 115: Locating Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

If equipped, attach the wiring harness retainer to the LH valve cover stud bolt.

Fig 116: Locating Wiring Harness Retainer

Courtesy of FORD MOTOR CO.

Connect the 3 LH coil-on-plug electrical connectors.
- Attach the 2 wiring harness pin-type retainers to the valve cover.

Fig 117: Locating LH Coil-On-Plug Electrical Connectors

Courtesy of FORD MOTOR CO.

Attach the 3 wiring harness retainers to the valve cover stud bolts.

Fig 118: Locating Wiring Harness Retainers From Valve Cover Stud Bolts

Courtesy of FORD MOTOR CO.

Connect the LH VCT solenoid and LH CMP sensor electrical connectors.
- Attach the 2 wiring harness retainers to the valve cover stud bolts.

Fig 119: Locating LH Variable Camshaft Timing Solenoid And LH Camshaft Position Sensor Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the generator B+ cable and electrical connector and install the nut.
- Tighten to 6 Nm (53 lb-in).

Fig 120: Locating Generator B+ Cable, Electrical Connector And Nut

Courtesy of FORD MOTOR CO.

Connect the EOP switch electrical connector and wiring harness retainer.

Fig 121: Identifying Engine Oil Pressure (EOP) Switch Electrical Connector & Wiring Harness Retainer

Courtesy of FORD MOTOR CO.

If equipped, attach the block heater wiring harness retainers to the oil level indicator tube and remove the harness.

Fig 122: Locating Block Heater Wiring Harness Retainers

Courtesy of FORD MOTOR CO.

If equipped, connect the block heater electrical connector.

Fig 123: Locating Block Heater Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the A/C compressor electrical connector and the wiring harness retainer.

Fig 124: Identifying A/C Compressor Electrical Connector & Wiring Harness Retainer

Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

Position the upper intake manifold and install the 8 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 125: Identifying Tightening Sequence Of Upper Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

Connect the Throttle Body (TB) coolant hose.

Fig 126: Locating Throttle Body Coolant Hose

Courtesy of FORD MOTOR CO.

Connect the electronic TB electrical connector.

Fig 127: Locating Electronic Throttle Body Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the crankcase vent hose to the upper intake manifold.

Fig 128: Locating Crankcase Vent Hose From Upper Intake Manifold

Courtesy of FORD MOTOR CO.

Attach the wiring harness pin-type retainer to the upper intake manifold.

Fig 129: Locating Wiring Harness Pin-Type Retainer

Courtesy of FORD MOTOR CO.

Connect the Manifold Absolute Pressure (MAP) sensor electrical connector and the pin-type retainer.

Fig 130: Locating Manifold Actual Pressure Sensor Electrical Connector And Pin-Type Retainer

Courtesy of FORD MOTOR CO.

NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.

Install the lower half of the Engine Lifting Bracket Set.

Fig 131: Identifying Lower Half Of Lifting Hook

Courtesy of FORD MOTOR CO.

Install the upper half of the Engine Lifting Bracket Set.

Fig 132: Identifying Upper Half Of Lifting Hook

Courtesy of FORD MOTOR CO.

Install the Engine Lifting Bracket.

Fig 133: Identifying Special Tools (134-00243)

Courtesy of FORD MOTOR CO.

Install the Engine Lifting Bracket and the Universal Adapter Bracket.

Fig 134: Identifying Special Tools (303-050 And 014-0001)

Courtesy of FORD MOTOR CO.

Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, remove the engine from the engine stand.

Fig 135: Identifying Special Tools (134-00243, 303-050, 303-1140, 303-D089)

Courtesy of FORD MOTOR CO.