Section 79 (Engine Mechanical - 5.4L (4V)): Assembly: Engine

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Compressor, Piston Ring	303-D032 (D81L-6002-C) or equivalent
Courtesy of FORD MOTOR CO.	Compressor, Valve Spring	303-452 (T93P-6565-AR)
Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane	014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Holding Tool, Crankshaft	303-448 (T93P-6303-A)
Courtesy of FORD MOTOR CO.	Installer, Connecting Rod	303-442 (T93P-6136-A)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Front Oil Seal	303-635
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Oil Slinger	303-517 (T95P-6701-CH)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Oil Seal	303-516 (T95P-6701-BH)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Oil Seal	303-518 (T95P-6701-DH)
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.	Lifting Bracket, Engine	303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Lifting Bracket, Engine (2 required)	303-D087 (D93P-6001-A1) or equivalent
Courtesy of FORD MOTOR CO.	Strap Wrench	303-D055 (D85L-6000-A) or equivalent

Material

Item	Specification
Motorcraft Metal Surface Prep ZC-31-A	-
Motorcraft SAE 5W-50 Full Synthetic Motor Oil XO-5W50-QGT or equivalent	WSS-M2C931-B
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Silicone Gasket Remover ZC-30	-

Fig 1: Exploded View Of Upper End Components & Front End Accessory Drive (FEAD) Components

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	10300	Generator
2	3A696	Power steering pump
3	8620	Supercharger (SC) drive belt
4	6B209	SC drive belt tensioner
5	19A216	SC drive belt heavy load idler pulley
6	19A216	SC drive belt smooth idler pulley
7	6C348	SC drive belt grooved idler pulley
8	8620	Engine accessory drive belt
9	19A216	Engine accessory drive belt grooved idler pulley
10	19A216	Engine accessory drive belt smooth idler pulley
11	6B209	Engine accessory drive belt tensioner
12	6584	RH valve cover gasket
13	6582	RH valve cover
14	6P067	RH ignition coil-on-plug cover
15	18801	RH radio interference capacitor
16	9H487	Intake manifold assembly
17	9439	Intake manifold assembly gasket (2 required)
18	9E822	Throttle Body (TB) assembly
19	18801	LH radio interference capacitor
20	6P067	LH ignition coil-on-plug cover
21	12A366	Ignition coil-on-plug (8 required)
22	6A505	LH valve cover
23	6584	LH valve cover gasket

Fig 2: Exploded View Of Lower End Components & Coolant Pump

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6675	Oil pan
2	6710	Oil pan gasket
3	6622	Oil pump screen and pickup tube
4	6325	Main bearing cap
5	6A338	Crankshaft lower main bearing (5 required)
6	6K302	Crankshaft lower thrust washer
7	6303	Crankshaft
8	6A341	Crankshaft upper thrust washers (2 required)
9	6621	Oil pump
10	6333	Crankshaft upper main bearing (5 required)
11	8501	Coolant pump
12	8A528	Coolant pump pulley
13	6010	Cylinder block

Fig 3: Exploded View Of Oil Filter Adapter Assembly

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	18663	Coolant tube assembly
2	6884	Oil filter adapter
3	6A636	Oil filter adapter gasket
4	6714	Engine oil filter
5	6A642	Oil cooler
6	6N818	Oil cooler gasket (4 required)

Fig 4: Exploded View Of Timing Drive Components & Cylinder Heads

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	12A227	Crankshaft sensor ring
2	6378	Crankshaft washer
3	6K255	RH timing chain tensioner arm
4	6306	Crankshaft timing sprocket
5	6268	LH primary timing chain
6	6B274	LH primary timing chain guide
7	6L266	RH primary timing chain tensioner
8	6268	RH primary timing chain
9	6M256	RH primary timing chain guide
10	6L266	LH primary timing chain tensioner
11	6M274	LH timing chain tensioner arm
12	6316	Crankshaft pulley
13	6700	Crankshaft front seal
14	6C086	Engine front cover
15	6D081	Engine front cover gasket
16	6F093	RH cylinder head assembly
17	6M099	LH cylinder head assembly

Fig 5: Exploded View Of Flywheel & Exhaust Manifolds

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	9D477	EGR tube
2	9428	RH exhaust manifold
3	9Y431	RH exhaust manifold gasket (2 required)
4	6375	Flywheel
5	6A373	Engine-to-transmission spacer plate
6	6310	Crankshaft oil slinger
7	6701	Crankshaft rear seal
8	6K318	Crankshaft rear seal retainer plate
9	18C553	Coolant tube assembly
10	9431	LH exhaust manifold
11	9Y431	LH exhaust manifold gasket (2 required)
12	6754	Oil level indicator tube assembly

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: During engine assembly it may become necessary to check bearing clearances and end play. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Record the first character code information on the cylinder block.

Fig 6: Recording First Character Code Information On Cylinder Block

Courtesy of FORD MOTOR CO.

Note the first character on the No. 7 crankshaft counterweight.

Fig 7: Identifying Main Bearing Code Found On Crankshaft Counterweight

Courtesy of FORD MOTOR CO.

Using the data recorded in the previous 2 steps, cross-reference using the chart to obtain bearing grade.

Fig 8: Bearing Select Fit Chart (Standard 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.

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

Fig 9: Lubricating Upper Crankshaft Main Bearings With Clean Engine Oil

Courtesy of FORD MOTOR CO.

NOTE: Do not install the upper thrust bearings until the crankshaft is installed.

NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.

Install the crankshaft onto the upper main bearings.

Fig 10: Installing Crankshaft Onto Upper Main Bearings

Courtesy of FORD MOTOR CO.

NOTE: Make sure the side of the thrust washer, with three 5-mm wide oil grooves, faces the crankshaft thrust surface.

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

Fig 11: Installing Rear Crankshaft Upper Thrust Washer

Courtesy of FORD MOTOR CO.

NOTE: Make sure the side of the thrust washer, with three 5-mm wide oil grooves, faces the crankshaft thrust surface.

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

Fig 12: Identifying Front Upper Crankshaft Thrust Washer

Courtesy of FORD MOTOR CO.

NOTE: Make sure the side of the thrust washer, with three 5-mm wide oil grooves, faces the crankshaft thrust surface.

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

Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with the tab aligned with the cutout in the main bearing cap.

Fig 13: Installing Lower Crankshaft Thrust Washer To Back Side Of No. 5 Main Bearing Cap

Courtesy of FORD MOTOR CO.

Lubricate the crankshaft lower main bearings and install them into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new cap fasteners.

NOTE: Crankshaft not shown for clarity.

Install the main bearing cap dowel pins so the flat sides face the crankshaft.

Fig 14: Lubricating Crankshaft Lower Main Bearings & Installing Them Into Main Bearing Caps

Courtesy of FORD MOTOR CO.

Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.

Fig 15: Pushing Crankshaft Forward To Seat Crankshaft Thrust Washer

Courtesy of FORD MOTOR CO.

Tighten the vertical main bearing cap fasteners in the sequence shown, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 40 Nm (30 lb-ft).
- Stage 3: Tighten an additional 90 degrees.

Fig 16: Tightening Vertical Main Bearing Cap Fasteners In Sequence

Courtesy of FORD MOTOR CO.

NOTE: Crankshaft not shown for clarity.

Install the new side bolts and tighten them in the sequence shown, in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 17: Installing New Side Bolts In Sequence

Courtesy of FORD MOTOR CO.

Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
Check the crankshaft end play. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

NOTE: Verify correct orientation of connecting rod and rod cap.

Prepare the connecting rod and cap.
- Insert the bolts in the rod cap.
- Insert the upper and lower rod bearings into the rod and cap.

Fig 18: Positioning Bearing, Rod Cap & Bolts

Courtesy of FORD MOTOR CO.

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

NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown.

NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.

Using the Piston Ring Compressor and the Connecting Rod Installer, install the No. 1 and No. 6 piston and the connecting rod assemblies.
- Lubricate the piston and rings with clean engine oil.
- Lubricate the rod bearings with clean engine oil.
- Lubricate the cylinder bores with clean engine oil.

Fig 19: Installing No. 1 & No. 6 Piston & Connecting Rod Assemblies Using Special Tools (303-442) & (303-D032)

Courtesy of FORD MOTOR CO.

Seat the connecting rods on the crankshaft journals and remove the Connecting Rod Installer.

Fig 20: Identifying Special Tool (303-442)

Courtesy of FORD MOTOR CO.

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

NOTE: Rotate the crankshaft after each connecting rod is installed and tightened, to check for assembly binding.

Install the rod bearing caps and tighten the bolts in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 21: Identifying Rod Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

Install the piston assemblies 3 and 5, 4 and 7, 2 and 8, by turning the crankshaft 90 degrees and repeating the previous steps.
Install the windage tray, the 7 nuts and the spacer.
- Tighten in the sequence shown to 25 Nm (18 lb-ft).

Fig 22: Installing Windage Tray Nuts & Spacer In Sequence

Courtesy of FORD MOTOR CO.

Install the oil pump and 3 bolts.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).

Fig 23: Installing Oil Pump Bolts In Sequence

Courtesy of FORD MOTOR CO.

NOTE: Install a new O-ring seal on the oil pump screen and pickup tube.

Install the oil pump screen and pickup tube and the 3 bolts.
- Tighten the 2 small bolts to 10 Nm (89 lb-in).
- Tighten the large bolt to 25 Nm (18 lb-ft).

Fig 24: Identifying Bolts, Oil Pump Screen & Pickup Tube Assembly

Courtesy of FORD MOTOR CO.

NOTE: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. Failure to follow these instructions may result in engine damage. For additional information, refer to Cylinder Head .

NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.

NOTE: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.

NOTE: RH head gasket shown, LH head gasket similar.

Install the RH and LH head gasket over the dowel pins.

Fig 25: Head Gasket & Dowel Pins

Courtesy of FORD MOTOR CO.

NOTE: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area. Failure to follow these instructions may result in engine damage.

NOTE: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. 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: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.

NOTE: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation. Failure to follow these instructions may result in engine damage.

NOTE: LH shown, RH similar.

Install the RH and LH cylinder heads on the dowels and the head gaskets.
- Loosely install new bolts.

Fig 26: Identifying Cylinder Head Bolts

Courtesy of FORD MOTOR CO.

Tighten the new RH cylinder head bolts in 5 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 50 Nm (37 lb-ft).
- Stage 3: Tighten to 80 Nm (59 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
- Stage 5: Tighten an additional 90 degrees.

Fig 27: Tightening New Cylinder Head Bolts In Sequence

Courtesy of FORD MOTOR CO.

Tighten the new LH cylinder head bolts in 5 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 50 Nm (37 lb-ft).
- Stage 3: Tighten to 80 Nm (59 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
- Stage 5: Tighten an additional 90 degrees.

Fig 28: Tightening New Cylinder Head Bolts In Sequence

Courtesy of FORD MOTOR CO.

NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using an edge of a vise.

Fig 29: Compressing Tensioner Plunger

Courtesy of FORD MOTOR CO.

Using a small screwdriver or pick, push back and hold the ratchet mechanism.

Fig 30: Pushing Back And Holding Ratchet Mechanism

Courtesy of FORD MOTOR CO.

While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 31: Compressing Tensioner Plunger

Courtesy of FORD MOTOR CO.

Install a suitable pin into the hole of each tensioner housing to hold the ratchet assembly and plunger in place during installation.
- Remove the tensioner from the vise.

Fig 32: Installing Paper Clip Into Tensioner Housing

Courtesy of FORD MOTOR CO.

If the colored links are not visible, mark one link on one end and 2 links on the other end, and use as timing marks.

Fig 33: Locating Timing Chain Marks

Courtesy of FORD MOTOR CO.

Using the Crankshaft Holding Tool, position the crankshaft.

Fig 34: Positioning Crankshaft With Special Tool (303-448)

Courtesy of FORD MOTOR CO.

Install the crankshaft sprocket with the flange facing forward.

Fig 35: Identifying Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Position the camshaft sprocket timing marks as shown.

Fig 36: Identifying Camshaft Sprocket Timing Marks

Courtesy of FORD MOTOR CO.

Install the LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 37: Locating LH Primary Timing Chain Guide Bolts

Courtesy of FORD MOTOR CO.

Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one colored link on the timing chain with the slot on the crankshaft sprocket.

Fig 38: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Install the LH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.

Fig 39: Aligning Timing Marks On Sprocket With Marked Chain Links

Courtesy of FORD MOTOR CO.

Install the LH primary timing chain tensioner arm.

Fig 40: Locating LH Primary Timing Chain Tensioner Arm

Courtesy of FORD MOTOR CO.

Install the LH primary timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Remove the pin from the tensioner.

Fig 41: Locating LH Primary Timing Chain Tensioner Bolts

Courtesy of FORD MOTOR CO.

Install the RH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 42: Locating RH Primary Timing Chain Guide Bolts

Courtesy of FORD MOTOR CO.

Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored link with the timing marks on the sprocket.

Fig 43: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Install the RH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.

Fig 44: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark

Courtesy of FORD MOTOR CO.

Install the RH primary timing chain tensioner arm.

Fig 45: Locating RH Primary Timing Chain Tensioner Arm

Courtesy of FORD MOTOR CO.

Install the RH primary timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Remove the pin from the tensioner.

Fig 46: Locating RH Primary Timing Chain Tensioner Bolts

Courtesy of FORD MOTOR CO.

As a post-check, verify correct alignment of all timing marks. Make sure that the colored links are lined up with the marks on the crankshaft sprocket and the camshaft sprockets.

Fig 47: Identifying Alignment Of All Timing Marks

Courtesy of FORD MOTOR CO.

Install the crankshaft washer.

Fig 48: Locating Crankshaft Washer

Courtesy of FORD MOTOR CO.

Install the crankshaft sensor ring.

Fig 49: Locating Crankshaft Sensor Ring

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed in their original positions or damage to the engine may occur.

Install the hydraulic lash adjusters.

Fig 50: Identifying Hydraulic Lash Adjusters

Courtesy of FORD MOTOR CO.

Using the Valve Spring Compressor, compress the valve spring and install the roller follower.

Fig 51: Using Special Tool (303-452) To Compress Valve Springs

Courtesy of FORD MOTOR CO.

Repeat the previous step to install all the roller followers.

NOTE: RH shown, LH similar.

Install the 8 spark plugs.
- Tighten to 18 Nm (159 lb-in).

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.

Apply silicone gasket and sealant in the locations shown.

Fig 52: Applying Silicone Gasket & Sealant

Courtesy of FORD MOTOR CO.

Using new gaskets, install the engine front cover and the 16 bolts. Tighten the bolts in the sequence shown:

* Bolts 1 through 14 to 25 Nm (18 lb-ft).

* Bolts 15 and 16 to 50 Nm (37 lb-ft).

Item	Part Number	Description
1	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
2	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
3	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
4	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
5	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
6	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
7	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
8	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
9	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
10	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
11	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
12	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
13	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
14	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
15	N606063	Bolt, hex flange head pilot, M10 x 1.50 x 55
16	N606063	Bolt, hex flange head pilot, M10 x 1.50 x 55

Fig 53: Installing Engine Front Cover Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

Fig 54: Lubricating Engine Front Cover And Crankshaft Front Seal Inner Lip

Courtesy of FORD MOTOR CO.

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

Fig 55: Installing Crankshaft Front Seal Using Special Tools (303-102, 303-335, 303-635)

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

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

Fig 56: Applying Silicone Gasket & Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.

Fig 57: Lubricating Crankshaft Pulley Sealing Surface With Clean Engine Oil Prior To Installation

Courtesy of FORD MOTOR CO.

Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

Fig 58: Installing Crankshaft Pulley Using Crankshaft Vibration Damper Installer

Courtesy of FORD MOTOR CO.

Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
- Stage 1: Tighten to 90 Nm (66 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 59: Removing Crankshaft Pulley Bolt & Washer Using Strap Wrench

Courtesy of FORD MOTOR CO.

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

Fig 60: Locating Coolant Pump Bolts

Courtesy of FORD MOTOR CO.

Install the Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 61: Locating CMP Sensor Bolt

Courtesy of FORD MOTOR CO.

Install the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 62: Locating Crankshaft Position (CKP) Sensor Bolt

Courtesy of FORD MOTOR CO.

Install new gaskets. Make sure the gaskets are correctly seated on the valve cover.

Fig 63: Locating Gaskets On Valve Cover

Courtesy of FORD MOTOR CO.

NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: LH shown, RH similar.

Apply silicone gasket and sealant to the engine front cover-to-cylinder block joints.

Fig 64: Applying Bead Of Silicone Gasket & Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Install the valve covers, bolts and stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 65: Tightening Valve Covers Bolts In Sequence

Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Install the LH and RH block drain plugs.
- Tighten to 14 Nm (124 lb-in).

Fig 66: Locating LH & RH Block Drain Plugs

Courtesy of FORD MOTOR CO.

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

Using a new O-ring seal, install the oil level indicator tube, bolt and oil level indicator.
- Tighten to 10 Nm (89 lb-in).

Fig 67: Identifying Oil Level Indicator Tube & Bolt

Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using a new gasket, install the oil filter adapter and the 8 bolts.
- Tighten in the sequence shown:
  - Bolts 1 through 6 to 25 Nm (18 lb-ft).
  - Bolts 7 and 8 to 50 Nm (37 lb-ft).

Fig 68: Installing Oil Filter Adapter Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

NOTE: A new cooler must be installed or severe damage to the engine can occur.

NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using new gaskets, install a new oil cooler and the 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 69: Installing Oil Cooler Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Install the coolant tube assembly and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 70: Identifying Coolant Tube Assembly Bolts

Courtesy of FORD MOTOR CO.

Install the 3 coolant tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 71: Identifying Coolant Tube Assembly Bolts

Courtesy of FORD MOTOR CO.

Install 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
Install new gaskets, the LH exhaust manifold and 8 new nuts.
- Tighten in the sequence shown to 20 Nm (177 lb-in).

Fig 72: Identifying LH Exhaust Manifold Nuts Tightening Sequence

Courtesy of FORD MOTOR CO.

Install the LH engine support insulator bracket and the 4 bolts.
- Tighten to 63 Nm (46 lb-ft).

Fig 73: Identifying LH Engine Support Insulator Bracket Bolts

Courtesy of FORD MOTOR CO.

Install 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
Install new gaskets, the RH exhaust manifold and 8 new nuts.
- Tighten in the sequence shown to 20 Nm (177 lb-in).

Fig 74: Identifying RH Exhaust Manifold Nuts Tightening Sequence

Courtesy of FORD MOTOR CO.

Install the RH engine support insulator bracket, the stud bolt, and the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).

Fig 75: Locating RH Engine Support Insulator Bracket Bolts & Stud Bolt

Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using new intake manifold gaskets, install the intake manifold and the 14 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 76: Identifying Intake Manifold Gasket Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Connect the intake manifold-to-coolant tube assembly hose.

Fig 77: Disconnecting Intake Manifold-To-Coolant Tube Assembly Hose

Courtesy of FORD MOTOR CO.

Position the wiring harness assembly onto the engine.

NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation.

Install the 4 LH coil-on-plugs.
- Connect the 4 LH coil-on-plug electrical connectors.

Fig 78: Disconnecting LH Coil-On-Plug Electrical Connectors

Courtesy of FORD MOTOR CO.

Install the LH coil-on-plug cover and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 79: Locating LH Coil-On-Plug Cover Bolts

Courtesy of FORD MOTOR CO.

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

Fig 80: Detaching Wiring Harness Retainers From LH Valve Cover Stud Bolts

Courtesy of FORD MOTOR CO.

Install the LH radio interference capacitor and the nut.
- Tighten to 10 Nm (89 lb-in).

Fig 81: Locating LH Radio Interference Capacitor Nut

Courtesy of FORD MOTOR CO.

Connect the 4 LH fuel injector electrical connectors.

Fig 82: Locating LH Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the Intake Air Temperature 2 (IAT2) sensor electrical connector.

Fig 83: Locating Intake Air Temperature (IAT) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the CMP sensor electrical connector.

Fig 84: Locating Camshaft Position (CMP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness pin-type retainers.

Fig 85: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation.

Install the 4 RH coil-on-plugs.
- Connect the 4 RH coil-on-plug electrical connectors.

Fig 86: Locating RH Coil-On-Plug Electrical Connectors

Courtesy of FORD MOTOR CO.

Install the RH coil-on-plug cover, bolt and stud bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 87: Locating RH Coil-On-Plug Cover Bolt & Stud Bolt

Courtesy of FORD MOTOR CO.

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

Fig 88: Detaching Wiring Harness Retainers From RH Valve Cover Stud Bolts

Courtesy of FORD MOTOR CO.

Attach the wiring harness to the RH coil-on-plug cover stud bolt.

Fig 89: Detaching Wiring Harness From RH Coil-On-Plug Cover Stud Bolt

Courtesy of FORD MOTOR CO.

Connect the EGR valve electrical connector.

Fig 90: Disconnecting EGR Valve Electrical Connector

Courtesy of FORD MOTOR CO.

Install the RH radio interference capacitor and the nut.
- Tighten to 10 Nm (89 lb-in).

Fig 91: Removing Nut & RH Radio Interference Capacitor

Courtesy of FORD MOTOR CO.

Connect the fuel rail pressure and temperature sensor electrical connector.

Fig 92: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the 4 RH fuel injector electrical connectors.

Fig 93: Locating RH Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the PCV valve electrical connector.

Fig 94: Locating Positive Crankcase Ventilation (PCV) Valve Electrical Connector

Courtesy of FORD MOTOR CO.

Attach the 2 wiring harness pin-type retainers.

Fig 95: Locating Wiring Harness Pin-Type Retainers

Courtesy of FORD MOTOR CO.

Install the wiring harness retaining bracket and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 96: Locating Wiring Harness Retaining Bracket & Bolts

Courtesy of FORD MOTOR CO.

Connect the bubbler tube from the Supercharger (SC).

Fig 97: Disconnecting Bubbler Tube From SC

Courtesy of FORD MOTOR CO.

Connect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.

Fig 98: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector & Pin-Type Retainer

Courtesy of FORD MOTOR CO.

Attach the 2 wiring harness pin-type retainers (1 shown) to the coolant tube assembly bracket.

Fig 99: Detaching Wiring Harness Pin-Type Retainer From Coolant Tube Assembly Bracket

Courtesy of FORD MOTOR CO.

Connect the Cylinder Head Temperature (CHT) sensor electrical connector.

Fig 100: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Install a new gasket, the Throttle Body (TB) and spacer assembly and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 101: Locating TB & Spacer Assembly Bolts

Courtesy of FORD MOTOR CO.

Connect the electronic throttle control electrical connector.

Fig 102: Locating Throttle Body (TB) Control Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the Throttle Position (TP) sensor electrical connector.

Fig 103: Locating Throttle Position (TP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Install and connect the crankcase ventilation tube.

Fig 104: Locating Crankcase Ventilation Tube

Courtesy of FORD MOTOR CO.

Install the EGR tube.
- Tighten to 40 Nm (30 lb-ft).

Fig 105: Locating Exhaust Gas Recirculation (EGR) Tube Fittings

Courtesy of FORD MOTOR CO.

Install the 3 SC drive belt idler pulleys and the 3 bolts.
- Tighten the heavy load idler pulley (closest to centerline of engine) to 48 Nm (35 lb-ft).
- Tighten the smooth idler pulley and the grooved idler pulley to 25 Nm (18 lb-ft).

Fig 106: Locating SC Drive Belt Idler Pulley Bolts

Courtesy of FORD MOTOR CO.

Install the coolant pump pulley and install the 4 bolts hand-tight.

Fig 107: Locating Coolant Pump Pulley Bolts

Courtesy of FORD MOTOR CO.

Install the accessory drive belt idler pulley (grooved) and the bolt.
- Tighten to 25 Nm (18 lb-ft).

Fig 108: Locating Accessory Drive Belt Idler Pulley Bolt

Courtesy of FORD MOTOR CO.

Install the accessory drive belt idler pulley (smooth) and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).

Fig 109: Locating Stud Bolt & Accessory Drive Belt Idler Pulley

Courtesy of FORD MOTOR CO.

Install the accessory drive belt tensioner and the bolt.
- Tighten to 25 Nm (18 lb-ft).

Fig 110: Locating Accessory Drive Belt Tensioner Bolt

Courtesy of FORD MOTOR CO.

Install the generator, 2 bolts and the stud bolt.
- Tighten to 50 Nm (37 lb-ft).

Fig 111: Locating Stud Bolt, Bolts & Alternator

Courtesy of FORD MOTOR CO.

Connect the generator electrical connector.

Fig 112: Locating Generator Electrical Connector

Courtesy of FORD MOTOR CO.

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

Fig 113: Locating Power Steering Pump & Reservoir Assembly Bolts

Courtesy of FORD MOTOR CO.

Install the power steering reservoir bracket bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 114: Locating Power Steering Reservoir Bracket Bolts

Courtesy of FORD MOTOR CO.

Install the power steering tube bracket bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 115: Locating Power Steering Tube Bracket Bolt

Courtesy of FORD MOTOR CO.

Install the power steering tube bracket nut.
- Tighten to 10 Nm (89 lb-in).

Fig 116: Locating Power Steering Tube Bracket Nut

Courtesy of FORD MOTOR CO.

Position the SC drive belt and install the SC drive belt tensioner and bolt.
- Tighten to 48 Nm (35 lb-ft).

Fig 117: Locating Bolt, Supercharger (SC) Drive Belt Tensioner & SC Drive Belt

Courtesy of FORD MOTOR CO.

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

Fig 118: Rotating Accessory Drive Belt Tensioner Clockwise & Removing Accessory Drive Belt

Courtesy of FORD MOTOR CO.

Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).

Fig 119: Locating Coolant Pump Pulley Bolts

Courtesy of FORD MOTOR CO.

Connect the coolant hose from the Charge Air Cooler (CAC).

Fig 120: Locating Coolant Hose From Charge Air Cooler (CAC)

Courtesy of FORD MOTOR CO.

Install the thermostat housing assembly and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).

Fig 121: Locating Thermostat Housing Assembly Nuts

Courtesy of FORD MOTOR CO.

Connect the Engine Coolant Temperature (ECT) sensor electrical connector.

Fig 122: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the 2 upper radiator hoses to the intake manifold.

Fig 123: Locating Upper Radiator Hoses From Intake Manifold

Courtesy of FORD MOTOR CO.

Connect the 2 coolant vent hoses to the intake manifold.

Fig 124: Locating Coolant Vent Hoses From The Intake Manifold

Courtesy of FORD MOTOR CO.

Install the coolant tube bracket nut.
- Tighten to 9 Nm (80 lb-in).

Fig 125: Locating Coolant Tube Bracket Nut

Courtesy of FORD MOTOR CO.

Connect the coolant hose to the thermostat housing.

Fig 126: Locating Coolant Hose From Thermostat Housing

Courtesy of FORD MOTOR CO.

Install the Engine Lifting Bracket.

Fig 127: Identifying Special Tool (303-D087)

Courtesy of FORD MOTOR CO.

Install the Engine Lifting Bracket.

Fig 128: Identifying Special Tool (303-D087)

Courtesy of FORD MOTOR CO.

Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, remove the engine from the work stand.

Fig 129: Removing Engine From Work Stand Using Special Tools (303-D089) & (014-00071)

Courtesy of FORD MOTOR CO.

Apply a 4 mm (0.15 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating surface on the engine block.

Fig 130: Applying Bead Of Gasket Maker To Rear Crankshaft Seal Retainer

Courtesy of FORD MOTOR CO.

Install the crankshaft rear seal retainer plate and the 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Fig 131: Tightening Sequence Of Crankshaft Rear Seal Retainer Plate Bolts

Courtesy of FORD MOTOR CO.

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

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

Fig 132: Using Special Tools To Install New Crankshaft Rear Seal

Courtesy of FORD MOTOR CO.

Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear seal.

Fig 133: Installing Crankshaft Rear Oil Slinger Using Special Tools

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.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing joints and the crankshaft rear seal retainer plate-to-cylinder block sealing joints.

Fig 134: Applying Silicone Gasket & Sealant At Engine Front Cover-To-Cylinder Block Sealing Joints

Courtesy of FORD MOTOR CO.

Using a new gasket, install the oil pan, 14 bolts and 2 stud bolts.
- Tighten in the sequence shown to 25 Nm (18 lb-ft).

Fig 135: Installing Oil Pan Bolts & Stud Bolts In Sequence

Courtesy of FORD MOTOR CO.

Install the engine/transmission spacer plate.

Fig 136: Locating Engine/Transmission Spacer Plate

Courtesy of FORD MOTOR CO.

Position the flywheel on the crankshaft pilot and start the 8 flywheel bolts.
Tighten the flywheel bolts evenly in the sequence shown to fully seat the flywheel on the crankshaft pilot.
- Tighten to 80 Nm (59 lb-ft).

Fig 137: Tightening Flywheel Bolts Evenly In Sequence

Courtesy of FORD MOTOR CO.