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Section 81 (Engine Mechanical - 4.0L SOHC): 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
GF0000237Courtesy of FORD MOTOR CO.
 Adapter for 303-564 303-578 (T97T-6256-A)
GF0000234Courtesy of FORD MOTOR CO.
 Adapter for 303-577 303-576 (T97T-6256-D)
GF0046301Courtesy of FORD MOTOR CO.
 Adapter for 303-579 (part of 303-S524) 303-527 (T95P-6701-A3)
GF0000248Courtesy of FORD MOTOR CO.
 Aligner, Front Cover 303-093 (T74P-6019-A)
GF0000291Courtesy of FORD MOTOR CO.
 Compressor, Piston Ring 303-D032 (D81L-6002-C)
GF0000262Courtesy of FORD MOTOR CO.
 Compressor, Valve Spring 303-581 (T97T-6565-A)
GF0000236Courtesy of FORD MOTOR CO.
 Holding Tool, Camshaft 303-577 (T97T-6256-C)
GF0000230Courtesy of FORD MOTOR CO.
 Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B)
GF0015125Courtesy of FORD MOTOR CO.
 Holding Tool, Crankshaft 303-674
GF0000251Courtesy of FORD MOTOR CO.
 Installer, Crankshaft Rear Oil Seal 303-579 (T97T-6701-A)
GF0000290Courtesy of FORD MOTOR CO.
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
GF0000292Courtesy of FORD MOTOR CO.
 Lifting Bracket, Engine 303-050 (T70P-6000)
GF0046302Courtesy of FORD MOTOR CO.
 Screws, Crankshaft Rear Oil Seal (part of 303-S524) 303-528 (T95T-6701-A4)
GF0000267Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0000246Courtesy of FORD MOTOR CO.
 Strap Wrench 303-D055 (85L-6000-A) or equivalent
GF0000231Courtesy of FORD MOTOR CO.
 Tensioner, Timing Chain 303-571 (T97T-6K254-A)
GF0000232Courtesy of FORD MOTOR CO.
 Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A)
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31-A		 -
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil
XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalent		 WSS-M2C929-A
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		 -
Thread Sealant with PTFE
TA-24		 WSK-M2G350-A2
Fig 1: Exploded View Of Engine Upper End
GF0015170Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6582 RH valve cover
2 6769 Electric PCV valve
3 9D280 RH fuel rail
4 9F593 Fuel injector (6 required)
5 9G512 Fuel injector insert adapter (6 required)
6 6A258 RH camshaft thrust bearing cap
7 6250 RH camshaft
8 8A586 Thermostat housing
9 9E469 EGR system module tube
10 6K817 PCV tube
11 9K479 Intake manifold
12 9E498 Vacuum harness
13 9E964 Fuel supply tube
14 9G756 Fuel rail pressure and temperature sensor
15 9D280 LH fuel rail
16 6A505 LH valve cover
17 6K254 LH hydraulic chain tensioner
18 6A258 LH camshaft thrust bearing cap
19 6A258 LH camshaft bearing cap (3 required)
20 6A274 LH camshaft
21 6529 Roller follower (12 required)
22 6518 Valve spring retainer key (12 required)
23 6A536 Valve spring retainer (12 required)
24 6C501 Hydraulic lash adjuster (12 required)
25 6513 Valve spring (12 required)
26 6571 Valve stem seal (12 required)
27 9448 LH exhaust manifold gasket
28 9431 LH exhaust manifold
29 6507 Intake valve (6 required)
30 6083 LH cylinder head gasket
31 6505 Exhaust valve (6 required)
32 12405 Spark plug (6 required)
33 6049 LH cylinder head
34 6049 RH cylinder head
35 6051 RH cylinder head gasket
36 6K254 RH hydraulic chain tensioner
37 9448 RH exhaust manifold gasket
38 9430 RH exhaust manifold
39 18696 Coolant tube
40 6A258 RH camshaft bearing cap (3 required)
Fig 2: Exploded View Of Engine Lower End
GF0015171Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6B321 Crankshaft pulley
2 6C315 Crankshaft Position (CKP) sensor
3 8501 Coolant pump
4 6700 Crankshaft front oil seal
5 8507 Coolant pump gasket
6 6019 Engine front cover
7 6020 Engine front cover gasket
8 6M270 Jackshaft chain
9 6M264 Jackshaft chain sprocket
10 6M271 Jackshaft chain tensioner
11 6M272 Jackshaft chain guide
12 6714 Oil filter
13 6884 Oil filter adapter
14 6L621 Oil filter adapter O-ring seal
15 12A699 Knock Sensor (KS)
16 6M290 RH camshaft drive cassette
17 6M289 LH camshaft drive cassette
18 6846 Oil pump drive assembly
19 6754 Oil level indicator tube
20 6750 Oil level indicator
21 6M296 Jackshaft seal
22 6M052 Jackshaft plug
23 6375 Flexplate
24 6434 Flexplate-to-crankshaft spacer
25 6701 Crankshaft rear oil seal
26 9278 Oil pressure sensor
27 6A311 Balance shaft (if equipped)
28 6K355 Balance shaft chain tensioner (if equipped)
29 6A364 Balance shaft chain (if equipped)
30 6375 Flywheel (manual transmission only)
31 6333 Crankshaft main bearing (3 required)
32 6337 Crankshaft main bearing cap
33 W702979 Woodruff key
34 6306 Jackshaft chain sprocket
35 6K350 Balance shaft chain sprocket (if equipped)
36 6A338 Crankshaft main bearing (3 required)
37 6303 Crankshaft
38 6A339 Crankshaft main bearing cap
39 6325 Crankshaft main thrust bearing
40 6A605 Oil pump drive shaft
41 6621 Oil pump
42 6C629 Shim (2 required)
43 6675 Oil pan
44 6617 Oil pump screen and pickup tube
45 6F092 Cylinder block cradle
46 6710 Cylinder block cradle gasket
47 6210 Connecting rod cap
48 6211 Connecting rod bearings
49 6200 Connecting rod
50 6135 Piston pin
51 6159 Oil control rings
52 6152 Lower compression ring
53 6150 Upper compression ring
54 6161 Oil control ring spacer
55 6110 Piston
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 fuel rail is used as a leverage device, damage may occur to the fuel rail. Care must be taken when working around the fuel rail.
  1. Install the crankshaft main bearings and the thrust bearing.
    • Lubricate the crankshaft main bearings with clean engine oil.
  2. Install the lower main bearings in the bearing caps.
    3. Fig 3: Locating Crankshaft Main Bearings And Thrust Bearing
    GF0015168Courtesy of FORD MOTOR CO.
    NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  3. Install the crankshaft.
    4. Fig 4: Locating Crankshaft Main Bearings & Thrust Bearing
    GF0000285Courtesy 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 may cause future oil leakage.
  4. Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
    5. Fig 5: Apply Silicone Gasket & Sealant To Rear Main Bearing Cap
    GF0000293Courtesy of FORD MOTOR CO.
  5. Install the main bearing caps in the order in which they were removed.
    6. Fig 6: Locating Crankshaft Main Bearing Caps
    GF0000294Courtesy of FORD MOTOR CO.
  6. Tighten the bolts in the sequence shown to 35 Nm (26 lb-ft) and then rotate an additional 57 degrees.
    7. Fig 7: Identifying Main Bearing Cap Bolts Tightening Sequence
    GF0009463Courtesy of FORD MOTOR CO.
  7. Check the piston to cylinder bore and ring clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
    8. NOTE: Lubricate the piston rings with clean engine oil.
  8. Install the piston rings.
  9. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
    10. Fig 8: Identifying Piston Ring Gaps Positioning
    GF0002551Courtesy of FORD MOTOR CO.
  10. Install the connecting rod bearings.
    11. Fig 9: Locating Connecting Rod Bearings
    GF0015172Courtesy of FORD MOTOR CO.
  11. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
    12. Fig 10: Locating Rubber Hose Pieces On Connecting Rod Bolts
    GF0000282Courtesy of FORD MOTOR CO.
    NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.
  12. Using the Piston Ring Compressor, install the pistons.
    • Rotate the crankshaft as necessary.
    13. Fig 11: Installing Piston Using Special Tool (303-D032)
    GF0009464Courtesy of FORD MOTOR CO.
    NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.
  13. Check the clearance of each connecting rod bearing. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  14. Rotate the crankshaft until the piston is at the bottom of its stroke.
    15. NOTE: For cylinders 1, 2 and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5 and 6, remove the opposite nut first.
  15. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
    16. Fig 12: Locating Connecting Rod Nut
    GF0000295Courtesy of FORD MOTOR CO.
  16. Tap on the nut until the bolt can be removed by hand.
    17. Fig 13: Locating Opposite Bolt
    GF0000296Courtesy of FORD MOTOR CO.
  17. Repeat the previous 2 steps for the opposite bolt.
  18. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.
    19. Fig 14: Locating Connecting Rod Cap
    GF0000297Courtesy of FORD MOTOR CO.
  19. Install the connecting rod cap in its original position.
  20. Install and tighten the connecting rod nuts finger-tight.
    21. Fig 15: Tightening Connecting Rod Nuts
    GF0000298Courtesy of FORD MOTOR CO.
  21. Tighten the connecting rod nuts simultaneously in 2 stages:
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
  22. Repeat the previous 4 steps for the remaining connecting rods.
  23. Rotate crankshaft until the No. 1 piston is at Top Dead Center (TDC).
  24. If equipped, install the balance shaft.
    1. Position the balance shaft assembly.
    2. Install the bolts and tighten to 27 Nm (20 lb-ft).
    25. Fig 16: Identifying Balance Shaft Assembly And Bolts
    GF0015173Courtesy of FORD MOTOR CO.
    NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete turns of the balance shaft may be required to find the correct position.
  25. Align the timing marks.
    • Install a 4 mm (0.16 in) pin to hold the shaft in place.
    26. Fig 17: Locating Timing Marks
    GF0015174Courtesy of FORD MOTOR CO.
  26. If equipped, install the balance shaft chain and crankshaft sprocket.
    27. Fig 18: Locating Balance Shaft Chain And Crankshaft Sprocket
    GF0015175Courtesy of FORD MOTOR CO.
  27. If equipped, install the balance shaft tensioner.
    1. Position the balance shaft tensioner.
    2. Install the 2 bolts and tighten to 29 Nm (21 lb-ft).
    3. Position the balance shaft chain guide, install the 2 bolts and tighten to 10 Nm (89 lb-in).
    4. Remove the pin from the tensioner.
    28. Fig 19: Locating Balance Shaft Tensioner, Bolts And Balance Shaft Chain Guide
    GF0015176Courtesy of FORD MOTOR CO.
  28. Position the oil pump intermediate shaft and the oil pump. Install the 2 bolts.
    • Tighten to 19 Nm (168 lb-in).
    29. Fig 20: Locating Oil Pump Intermediate Shaft, Oil Pump And Bolt
    GF0015161Courtesy of FORD MOTOR CO.
  29. Install the jackshaft.
    30. Fig 21: Locating Jackshaft
    GF0009455Courtesy of FORD MOTOR CO.
  30. Install the jackshaft thrust plate and bolts.
    • Tighten to 11 Nm (97 lb-in).
    31. Fig 22: Locating Jackshaft Thrust Plate & Bolts
    GF0000280Courtesy of FORD MOTOR CO.
  31. Position the LH cassette.
    32. Fig 23: Locating Cassette And Timing Chain
    GF0015076Courtesy of FORD MOTOR CO.
  32. Install the front cassette and the bolt.
    • Tighten to 19 Nm (168 lb-in).
    33. Fig 24: Locating Front Cassette & Bolt
    GF0000257Courtesy of FORD MOTOR CO.
  33. Position the jackshaft sprocket and chain.
    34. Fig 25: Locating Jackshaft Chain And Sprockets
    G03914213Courtesy of FORD MOTOR CO.
  34. Install the jackshaft chain guide and the 2 bolts.
    • Tighten to 19 Nm (168 lb-in).
    35. Fig 26: Locating Chain Guide & Bolts
    GF0000278Courtesy of FORD MOTOR CO.
  35. Install the jackshaft chain tensioner and the 2 bolts.
    • Tighten to 9 Nm (80 lb-in).
    36. Fig 27: Locating Chain Tensioner & Bolts
    GF0000255Courtesy of FORD MOTOR CO.
  36. Using the Crankshaft Holding Tool, hold the crankshaft.
    37. Fig 28: Holding Crankshaft Using Special Tool (303-674)
    GF0015162Courtesy of FORD MOTOR CO.
  37. Install the jackshaft sprocket bolt and tighten in 2 stages.
    • Stage 1: Tighten to 45 Nm (33 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    38. Fig 29: Locating Jackshaft Sprocket Bolt
    GF0000279Courtesy of FORD MOTOR CO.
  38. Install the oil pump drive and the bolt.
    • Tighten to 19 Nm (168 lb-in).
    39. Fig 30: Locating Oil Pump Drive
    GF0000277Courtesy of FORD MOTOR CO.
  39. Position the RH cassette.
    40. Fig 31: Locating Cassette And Timing Chain
    GF0015076Courtesy of FORD MOTOR CO.
  40. Position the rear jackshaft sprocket and the spacer on the jackshaft.
    • Loosely install the bolt.
    41. Fig 32: Locating Rear Jackshaft Sprocket Bolt
    GF0009454Courtesy of FORD MOTOR CO.
  41. Install the RH cassette bolt.
    • Tighten to 12 Nm (106-in).
    42. Fig 33: Locating RH Camshaft Drive Cassette Bolt & Spacer
    GF0000276Courtesy of FORD MOTOR CO.
  42. Using the Crankshaft Holding Tool, hold the crankshaft.
    43. Fig 34: Identifying Special Tool (303-674) & Jackshaft Sprocket Bolt
    GF0009338Courtesy of FORD MOTOR CO.
  43. Tighten the rear jackshaft sprocket bolt in 2 stages.
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
    44. Fig 35: Locating Rear Jackshaft Sprocket Bolt
    GF0009454Courtesy of FORD MOTOR CO.
  44. Install the jackshaft plug.
    45. Fig 36: Locating Rear Jackshaft Plug
    GF0000275Courtesy of FORD MOTOR CO.
  45. Position a new engine front cover gasket on the cylinder block.
    46. NOTE: Apply thread sealant to the stud bolts and make sure that the stud bolts are installed in their original positions.
  46. Position the front cover and loosely install the 5 bolts and the 5 stud bolts.
    47. Fig 37: Locating Front Cover Stud Bolts
    GF0015177Courtesy of FORD MOTOR CO.
  47. Use the Front Cover Aligner to align the front cover and tighten the bolts and stud bolts to 19 Nm (168 lb-in).
    48. Fig 38: Identifying Special Tool (303-093)
    GF0015178Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the seal lip with clean engine oil.
  48. Using the Front Cover Aligner and Crankshaft Vibration Damper Installer, install the crankshaft front oil seal.
    49. Fig 39: Identifying Special Tools (303-102, 303-093) & Crankshaft Front Oil Seal
    GF0009317Courtesy of FORD MOTOR CO.
    NOTE: Failure to back off the set screws may result in damage to the cylinder block cradle.
  49. Back the set screws off until they are below the cylinder block cradle boss.
    50. Fig 40: Locating Cylinder Block Cradle Boss Screw
    GF0015089Courtesy 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.
  50. Apply silicone in the 6 places shown.
    51. Fig 41: Locating Silicone Applying Area
    GF0009366Courtesy of FORD MOTOR CO.
  51. Position the lower block cradle and a new gasket.
    52. Fig 42: Locating Cylinder Block Cradle & Gasket Assembly
    GF0000301Courtesy of FORD MOTOR CO.
  52. Install and hand-tighten the 20 bolts and 2 nuts.
    53. Fig 43: Locating Cylinder Block Cradle & Gasket
    GF0000273Courtesy of FORD MOTOR CO.
  53. Install and hand-tighten the bolts.
    54. Fig 44: Locating Rear Cylinder Block Cradle Bolts
    GF0000302Courtesy of FORD MOTOR CO.
    NOTE: The lower block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) lower block cradle under flush or 0.05 mm (0.00196 in) lower block cradle protrusion.
  54. Using a straightedge, align the transmission face of the lower block cradle with the rear face of the cylinder block.
    55. Fig 45: Locating Transmission Face Of Cylinder Block Cradle With Rear Face Of Cylinder Block
    GF0009469Courtesy of FORD MOTOR CO.
  55. Tighten the 20 bolts and the 2 nuts.
    • Tighten the nuts to 10 Nm (89 lb-in).
    • Tighten the bolts to 14 Nm (124 lb-in).
    56. Fig 46: Locating Cylinder Block Cradle & Gasket
    GF0000273Courtesy of FORD MOTOR CO.
  56. Install the 2 block cradle bolts.
    • Tighten to 10 Nm (89 lb-in).
    57. Fig 47: Locating Rear Cylinder Block Cradle Bolts
    GF0000272Courtesy of FORD MOTOR CO.
  57. Tighten the lower block cradle inserts to 3 Nm (27 lb-in).
    58. Fig 48: Locating Cylinder Block Cradle Rear Torx Bolts
    GF0009367Courtesy of FORD MOTOR CO.
  58. Install new seals on the 2 silver bolts and loosely install them in the cylinder block cradle.
    59. Fig 49: Locating Silver-Colored Bolts And New Washer Seals
    GF0009368Courtesy of FORD MOTOR CO.
  59. Loosely install the 6 remaining lower block cradle bolts.
    60. Fig 50: Locating Lower Block Cradle Bolts
    GF0009470Courtesy of FORD MOTOR CO.
  60. Tighten the cylinder block cradle bolts in 2 stages.
    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Stage 2: Tighten to 34 Nm (25 lb-ft).
    61. Fig 51: Identifying Cylinder Block Cradle Inner Bolts Tightening Sequence
    GF0009369Courtesy of FORD MOTOR CO.
    NOTE: The cylinder block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) cylinder block cradle under flush or 0.05 mm (0.00196 in) cylinder block cradle protrusion.
  61. Using a straightedge, measure the mismatch between the transmission face of the cylinder block cradle with the rear face of the cylinder block.
    • Cradles that exceed protrusion specification must be removed and the appropriate assembly steps repeated.
    • Cradles that exceed the under flush specification may be repaired by installing shims (next step).
    62. Fig 52: Locating Transmission Face Of Cylinder Block Cradle With Rear Face Of Cylinder Block
    GF0009469Courtesy of FORD MOTOR CO.
  62. Repair all assemblies that exceed under flush specification by installing shims on 1 or both sides of the cylinder block cradle.
    63. Fig 53: Locating Shims On Both Sides Of Cylinder Block Cradle
    GF0000303Courtesy of FORD MOTOR CO.
  63. Install the oil pump screen and pickup tube and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    64. Fig 54: Locating Oil Pump Screen Cover And Bolt
    GF0009451Courtesy of FORD MOTOR CO.
  64. Install the gasket, oil pan and the 10 bolts.
    • Tighten to 11 Nm (97 lb-in).
    65. Fig 55: Locating Gasket, Oil Pan And Bolts
    GF0015160Courtesy of FORD MOTOR CO.
  65. Inspect and install new oil filter adapter O-ring seals if necessary.
    66. Fig 56: Locating O-Ring Seals
    GF0000304Courtesy of FORD MOTOR CO.
  66. Install the oil filter adapter and the bolt.
    • Tighten to 57 Nm (42 lb-ft).
    67. Fig 57: Locating Oil Filter Adapter
    GF0000274Courtesy of FORD MOTOR CO.
  67. Install a new oil filter.
    • Tighten until the oil filter seal is flush with the adapter and the tighten an additional 270 degrees.
    68. Fig 58: Locating Engine Oil Filter
    GF0015159Courtesy of FORD MOTOR CO.
  68. Using the Crankshaft Vibration Damper, install the crankshaft pulley.
    69. Fig 59: Installing Crankshaft Pulley Using Special Tool (303-102)
    GF0009315Courtesy of FORD MOTOR CO.
    NOTE: A new bolt must be used each time it is removed.
  69. Using the Strap Wrench, tighten the bolt in 2 stages.
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Rotate an additional 90 degrees.
    70. Fig 60: Holding Crankshaft Pulley Using Special Tool
    G03946937Courtesy of FORD MOTOR CO.
  70. Position the Crankshaft Position (CKP) sensor and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    71. Fig 61: Locating Crankshaft Position (CKP) Sensor And Bolts
    GF0015156Courtesy of FORD MOTOR CO.
    NOTE: LH side shown, RH side similar.
  71. Position the cylinder head gaskets.
    72. Fig 62: Identifying Cylinder Head Gaskets
    GF0000305Courtesy of FORD MOTOR CO.
    NOTE: To avoid damage to the timing chain cassette, an assistant will be required to help lift the cylinder head from the vehicle.
    NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
  72. Position the RH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten to 12 Nm (106 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    73. Fig 63: Identifying Tightening Sequence Of 12-MM Bolts
    GF0009327Courtesy of FORD MOTOR CO.
  73. Install 2 new M8 bolts.
    • Tighten to 32 Nm (24 lb-ft).
    74. Fig 64: Locating 8-Mm Bolts
    GF0009328Courtesy of FORD MOTOR CO.
  74. Tighten the 8 M12 bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten 90 degrees.
    • Stage 2: Tighten an additional 90 degrees.
    75. Fig 65: Identifying Tightening Sequence Of 12-MM Bolts
    GF0009327Courtesy of FORD MOTOR CO.
  75. Position the RH cassette and camshaft sprocket.
    76. Fig 66: Identifying Camshaft Sprocket From Camshaft
    GF0000306Courtesy of FORD MOTOR CO.
    NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt.
  76. Install and hand-tighten the RH rear camshaft sprocket bolt.
    77. Fig 67: Locating RH Camshaft Sprocket Bolt
    GF0000269Courtesy of FORD MOTOR CO.
  77. Install the RH cassette bolt.
    • Tighten to 10 Nm (89 lb-in).
    78. Fig 68: Locating RH Chain Guide Bolt
    GF0000270Courtesy of FORD MOTOR CO.
    NOTE: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
    NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
  78. Position the LH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten to 12 Nm (106 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    79. Fig 69: Identifying Cylinder Head Bolts Tightening Sequence
    GF0009330Courtesy of FORD MOTOR CO.
  79. Install 2 new M8 bolts.
    • Tighten to 32 Nm (24 lb-ft).
    80. Fig 70: Locating 8-Mm Bolts
    GF0009328Courtesy of FORD MOTOR CO.
  80. Tighten the 8 M12 bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten 90 degrees.
    • Stage 2: Tighten an additional 90 degrees.
    81. Fig 71: Identifying Cylinder Head Bolts Tightening Sequence
    GF0009330Courtesy of FORD MOTOR CO.
  81. Position the LH cassette and camshaft sprocket.
    82. Fig 72: Identifying Camshaft Sprocket From Camshaft
    GF0000306Courtesy of FORD MOTOR CO.
    NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt.
  82. Install and hand-tighten the LH camshaft sprocket bolt.
    83. Fig 73: Locating Camshaft Sprocket Bolt
    GF0000261Courtesy of FORD MOTOR CO.
  83. Install the LH cassette bolt.
    • Tighten to 12 Nm (106 lb-in).
    84. Fig 74: Locating Chain Guide Bolt
    GF0000256Courtesy of FORD MOTOR CO.
  84. Turn the crankshaft one revolution clockwise.
    85. NOTE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crank sensor speed wheel and incorrect timing of the engine.
    NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block, this positions the engine at Top Dead Center (TDC).
  85. Install the Crankshaft TDC Timing Tool.
    86. Fig 75: Identifying Special Tool (303-573)
    G03946899Courtesy of FORD MOTOR CO.
    NOTE: Camshaft timing slots are off-center.
    NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the Camshaft Holding Tool and Adapter.
  86. Install the Camshaft Holding Tool and Adapter on the front of the RH cylinder head.
    87. Fig 76: Identifying Special Tools (303-576, 303-577)
    G03946903Courtesy of FORD MOTOR CO.
    NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
  87. Install the Camshaft Sprocket Holding Tool and Adapter on the rear of the RH cylinder head.
    88. Fig 77: Identifying Special Holding Tool
    G03946909Courtesy of FORD MOTOR CO.
  88. Install the Timing Chain Tensioner.
    89. Fig 78: Identifying Special Tool (303-571)
    G03946905Courtesy of FORD MOTOR CO.
    NOTE: The RH camshaft sprocket bolt is a LH threaded bolt.
  89. Tighten the bolts.
    1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
    2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).
    90. Fig 79: Tightening Camshaft Sprocket Holding Tool Top Clamp Bolts
    GF0046299Courtesy of FORD MOTOR CO.
  90. Remove the Timing Chain Tensioner and install the RH camshaft tensioner.
    • Tighten to 44 Nm (32 lb-ft).
    91. Fig 80: Identifying Special Tool (303-571)
    G03946905Courtesy of FORD MOTOR CO.
    NOTE: Do not tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts. Camshaft sprocket must rotate freely.
  91. Install the Camshaft Sprocket Holding Tool and Adapter on the front of the LH cylinder head.
    92. Fig 81: Identifying Special Holding Tool
    G03946909Courtesy of FORD MOTOR CO.
    NOTE: Camshaft timing slots are off-center.
    NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the Camshaft Holding Tool and Adapter.
  92. Install the Camshaft Holding Tool and Adapter on the rear of the LH cylinder head.
    93. Fig 82: Identifying Special Tools (303-576, 303-577)
    G03946903Courtesy of FORD MOTOR CO.
  93. Install the Timing Chain Tensioner.
    94. Fig 83: Identifying Special Tool (303-571)
    GF0009299Courtesy of FORD MOTOR CO.
  94. Tighten the bolts.
    1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
    2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).
    95. Fig 84: Tightening Camshaft Sprocket Holding Tool Top Clamp Bolts
    GF0046299Courtesy of FORD MOTOR CO.
  95. Install a new washer and the LH camshaft tensioner.
    96. Fig 85: Locating Camshaft Tensioner
    G03913851Courtesy of FORD MOTOR CO.
  96. Rotate the crankshaft until the cam lobe is in the upward position.
    97. Fig 86: Locating Crankshaft Lobe
    GF0009348Courtesy of FORD MOTOR CO.
    NOTE: Install the hydraulic lash adjusters in the same positions from which they were removed.
  97. Install the hydraulic lash adjusters.
    98. Fig 87: Locating Hydraulic Lash Adjusters
    GF0000287Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the roller followers with clean engine oil.
  98. Using the Valve Spring Compressor, install the roller followers in their original positions.
    99. Fig 88: Removing/Installing Camshaft Roller Followers Using Special Tool (303-581)
    GF0009447Courtesy of FORD MOTOR CO.
  99. Position the RH engine mount bracket and install the 4 bolts.
    • Tighten to 80 Nm (59 lb-ft).
    100. Fig 89: Locating Engine Mount Bracket Bolts
    GF0015155Courtesy of FORD MOTOR CO.
  100. Install the 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
    101. Fig 90: Locating RH Exhaust Manifold Studs
    GF0046313Courtesy of FORD MOTOR CO.
  101. Position a new RH exhaust manifold gasket and the RH exhaust manifold. Install the 6 new nuts.
    • Tighten to 23 Nm (17 lb-ft).
    102. Fig 91: Locating Exhaust Manifold Nuts
    GF0015154Courtesy of FORD MOTOR CO.
  102. Position the LH engine mount bracket and install the 3 bolts.
    • Tighten to 80 Nm (59 lb-ft).
    103. Fig 92: Locating Engine Mount Bracket Bolts
    GF0015153Courtesy of FORD MOTOR CO.
  103. Install the 6 new LH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
    104. Fig 93: Locating Exhaust Manifold Studs
    GF0046305Courtesy of FORD MOTOR CO.
  104. Position a new LH exhaust manifold gasket and the LH exhaust manifold. Install the 6 new nuts.
    • Tighten to 23 Nm (17 lb-ft).
    105. Fig 94: Locating Exhaust Manifold Nuts
    GF0015152Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil.
  105. Position the oil level indicator tube and install the bolt.
    • Tighten to 11 Nm (97 lb-in).
    106. Fig 95: Locating Oil Level Indicator Tube And Bolt
    GF0015063Courtesy of FORD MOTOR CO.
  106. Clean the valve covers and cylinder head sealing surfaces with metal surface prep. Inspect and install new gaskets as necessary.
  107. Position the RH valve cover and install the 2 bolts and the 4 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    108. Fig 96: Identifying Valve Cover Bolts Tightening Sequence
    GF0015041Courtesy of FORD MOTOR CO.
  108. Position the LH valve cover and install the 3 bolts and the 3 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    109. Fig 97: Identifying Valve Cover Tightening Sequence
    GF0015039Courtesy of FORD MOTOR CO.
  109. Position the thermostat housing, hoses and coolant tube. Install the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
    110. Fig 98: Locating Thermostat Housing Hoses Bolts
    GF0015149Courtesy of FORD MOTOR CO.
  110. Connect the coolant hose to the coolant pump, position the bracket and install the bolt.
    • Tighten to 45 Nm (33 lb-ft).
    111. Fig 99: Locating Coolant Pump Bracket Bolts
    GF0015148Courtesy of FORD MOTOR CO.
  111. Position the Knock Sensor (KS) and install the bolt.
    • Tighten to 20 Nm (177 lb-in).
    112. Fig 100: Locating Knock Sensor Bolt
    GF0015147Courtesy of FORD MOTOR CO.
    NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings seals can cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: Lubricate the O-ring seals with clean engine oil.
  112. Install new O-ring seals on the 6 fuel injectors.
    113. Fig 101: Identifying Fuel Injector O-Ring Seals
    GF0000307Courtesy of FORD MOTOR CO.
  113. Position the fuel rail and injectors and install the 4 bolts.
    • Tighten to 23 Nm (17 lb-ft).
    114. Fig 102: Locating Fuel Rail And Injectors Bolts
    GF0015072Courtesy of FORD MOTOR CO.
  114. Position the main engine wiring harness on the engine and install the 3 bolts.
    • Tighten to 40 Nm (30 lb-ft).
    • Attach the wiring retainers.
    115. Fig 103: Locating Main Engine Wiring Harness And Bolts
    GF0015146Courtesy of FORD MOTOR CO.
  115. Connect the 3 RH fuel injector electrical connectors and attach the wiring retainer to the valve cover stud bolt.
    116. Fig 104: Locating Fuel Injector Electrical Connectors
    GF0015145Courtesy of FORD MOTOR CO.
  116. Connect the 3 LH fuel injector electrical connectors and attach the wiring retainer to the valve cover stud bolt.
    117. Fig 105: Locating Fuel Injector Electrical Connectors
    GF0015144Courtesy of FORD MOTOR CO.
  117. Connect the PCV valve electrical connector.
    118. Fig 106: Locating PCV Valve Electrical Connector
    GF0015143Courtesy of FORD MOTOR CO.
  118. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
    119. Fig 107: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
    GF0015142Courtesy of FORD MOTOR CO.
  119. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring retainers.
    120. Fig 108: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    GF0015141Courtesy of FORD MOTOR CO.
  120. Position the generator and bracket. Install the 2 bolts and the nut.
    • Tighten to 47 Nm (35 lb-ft).
    121. Fig 109: Locating Generator Bracket Bolt And Nut
    GF0015140Courtesy of FORD MOTOR CO.
  121. Install the accessory drive belt tensioner and the bolt.
    • Tighten to 47 Nm (35 lb-ft).
    122. Fig 110: Locating Belt Tensioner Bolt
    GF0015057Courtesy of FORD MOTOR CO.
  122. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.
    123. Fig 111: Locating Oil Pressure Sensor Electrical Connector
    GF0015139Courtesy of FORD MOTOR CO.
  123. Connect the Camshaft Position (CMP) electrical connector.
    124. Fig 112: Locating Camshaft Position (CMP) Electrical Connector
    GF0015138Courtesy of FORD MOTOR CO.
  124. Position the fuel rail supply tube brackets and install the 2 bolts.
    • Tighten the bolt for the upper bracket to 6 Nm (53 lb-in).
    • Tighten the bolt for the lower bracket to 10 Nm (89 lb-in).
    125. Fig 113: Locating Fuel Supply Tube Bracket Bolts
    GF0015137Courtesy of FORD MOTOR CO.
    NOTE: Clean and inspect all sealing surfaces. Inspect and install new intake manifold gaskets as necessary.
  125. Position the intake manifold and install the 8 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    126. Fig 114: Identifying Intake Manifold Bolt Tightening Sequence
    GF0015037Courtesy of FORD MOTOR CO.
  126. Connect the KS electrical connector and attach the wiring retainer.
    127. Fig 115: Locating Knock Sensor (KS) Electrical Connector
    GF0015135Courtesy of FORD MOTOR CO.
  127. Install the PCV tube.
    128. Fig 116: Locating Positive Crankcase Ventilation (PCV) Tube Fittings
    GF0015134Courtesy of FORD MOTOR CO.
  128. Position the EGR tube. Connect the fitting to the LH exhaust manifold.
    • Tighten to 40 Nm (30 lb-ft).
    129. Fig 117: Locating Exhaust Gas Recirculation (EGR) Tube
    GF0015133Courtesy of FORD MOTOR CO.
  129. Connect the EGR tube fitting to the EGR system module.
    • Tighten to 40 Nm (30 lb-ft).
    130. Fig 118: Locating EGR Tube Fitting On EGR System Module
    GF0015132Courtesy of FORD MOTOR CO.
  130. Connect the EGR system module and Throttle Position (TP) sensor electrical connectors.
    131. Fig 119: Locating EGR System Module And Throttle Position (TP) Sensor Electrical Connectors
    GF0015131Courtesy of FORD MOTOR CO.
  131. Connect the fuel rail pressure and temperature sensor electrical connector and the vacuum tube.
    132. Fig 120: Locating Fuel Rail Pressure And Temperature Sensor Electrical Connector
    GF0015130Courtesy of FORD MOTOR CO.
  132. Attach the B+ terminal to the generator and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    • Attach the wiring retainer to the generator.
    133. Fig 121: Locating Wiring Retainer On Generator Nut
    GF0015129Courtesy of FORD MOTOR CO.
  133. Connect the generator and Throttle Body (TB) electrical connectors.
    134. Fig 122: Locating Generator And Throttle Body Electrical Connectors
    GF0015128Courtesy of FORD MOTOR CO.
  134. Install the Engine Lifting Bracket to the RH cylinder head.
    135. Fig 123: Installing Special Tool 303-050 To RH Cylinder Head
    GF0009419Courtesy of FORD MOTOR CO.
  135. Install the Engine Lifting Bracket to the LH cylinder head.
    136. Fig 124: Installing Special Tool 303-050 To LH Cylinder Head
    GF0009417Courtesy of FORD MOTOR CO.
  136. Using the Spreader Bar and Engine Lifting Brackets, remove the engine from the engine stand.
    137. Fig 125: Removing Engine From Engine Stand Using Special Tools (303-050) & (303-D089)
    GF0015179Courtesy of FORD MOTOR CO.
    NOTE: The new replacement crankshaft rear seal comes with a speedy sleeve. Do not remove the speedy sleeve, it must be installed with the crankshaft rear seal.
    NOTE: Be sure the crankshaft rear sealing surface is clean and free from any rust or corrosion. To clean the crankshaft rear seal surface area, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface prep.
  137. Lubricate the crankshaft rear oil seal with clean engine oil.
  138. Install the Crankshaft Rear Oil Seal Screws and Adapter.
    139. Fig 126: Identifying Special Tool (303-527, 303-528)
    GF0009374Courtesy of FORD MOTOR CO.
  139. Position the crankshaft rear oil seal with speedy sleeve around the Crankshaft Rear Oil Seal Screws and Adapter.
    140. Fig 127: Identifying Crankshaft Rear Seal, Special Tool (303-527, 303-528)
    GF0009375Courtesy of FORD MOTOR CO.
  140. Using the Crankshaft Rear Oil Seal Installer, install the crankshaft rear oil seal with speedy sleeve.
    141. Fig 128: Identifying Special Tool (303-579)
    GF0009376Courtesy of FORD MOTOR CO.
  141. Install the spacer plate and if equipped, the flexplate-to-crankshaft spacer.
    142. Fig 129: Locating Spacer Plate Crankshaft Spacer
    GF0015127Courtesy of FORD MOTOR CO.
    NOTE: Special bolts are used for flexplate and flywheel installation. Do not use standard bolts.
  142. Install the flexplate or flywheel.
    • Tighten the bolts in the sequence shown in 3 stages.
      • Stage 1: Tighten to 13 Nm (115 lb-in).
      • Stage 2: Tighten to 50 Nm (37 lb-ft).
      • Stage 3: Tighten an additional 90 degrees.
    143. Fig 130: Identifying Flexplate Bolts Tightening Sequence
    GF0015045Courtesy of FORD MOTOR CO.
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