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Disassembly And Assembly: Engine: Material

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

Item Specification
Motorcraft® Metal Surface Prep ZC-31-A -
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 may cause engine failure.
NOTE: For additional information, refer to the exploded view under the Assembly procedure.

All vehicles 

  1. Remove the bolts and the flexplate.
    Fig 1: Locating Flexplate Bolts
    G06095704Courtesy of FORD MOTOR CO.
  2. Remove the engine-to-transaxle separator plate.
    Fig 2: Locating Engine-To-Transaxle Separator Plate
    G06095705Courtesy of FORD MOTOR CO.
  3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear oil seal.
    Fig 3: Removing Discard Crankshaft Rear Oil Seal
    G06095515Courtesy of FORD MOTOR CO.
  4. Mount the engine on a suitable stand.
  5. Disconnect the engine block Knock Sensor (KS) electrical connector and detach the wire harness retainer, disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
    Fig 4: Locating Engine Block Knock Sensor Electrical Connector
    G06095707Courtesy of FORD MOTOR CO.
  6. Disconnect the electronic throttle control electrical connector.
    Fig 5: Locating Electronic Throttle Control Electrical Connector
    G06095708Courtesy of FORD MOTOR CO.
  7. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 6: Locating Evaporative Emission Canister Purge Valve Electrical Connector
    G06095709Courtesy of FORD MOTOR CO.
  8. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
    Fig 7: Locating EGR Regulator Electrical Connector
    G06095710Courtesy of FORD MOTOR CO.
  9. Detach the wiring harness retainer from the upper intake manifold.
    Fig 8: Locating Wiring Harness Retainer
    G06095711Courtesy of FORD MOTOR CO.
  10. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
    Fig 9: Locating Manifold Absolute Pressure Electrical Connector
    G06095712Courtesy of FORD MOTOR CO.
  11. Disconnect the RH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 10: Locating RH Coil-On-Plug Electrical Connectors
      G06095713Courtesy of FORD MOTOR CO.

      Front Wheel Drive (FWD) vehicles 

  12. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 11: Locating RH Heated Oxygen Sensor Electrical Connector
    G06095714Courtesy of FORD MOTOR CO.

    All vehicles 

  13. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector.
    Fig 12: Locating RH Variable Camshaft Timing Electrical Connector
    G06095715Courtesy of FORD MOTOR CO.
  14. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
    Fig 13: Locating Crankshaft Position Sensor Electrical Connector
    G06095716Courtesy of FORD MOTOR CO.
  15. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
    Fig 14: Locating Camshaft Position Sensor Electrical Connectors
    G06095717Courtesy of FORD MOTOR CO.
  16. Disconnect the fuel injector wiring harness electrical connector.
    Fig 15: Locating Fuel Injector Wiring Harness Electrical Connector
    G06095718Courtesy of FORD MOTOR CO.
  17. Disconnect the LH VCT electrical connector.
    Fig 16: Locating LH VCT Electrical Connector
    G06095719Courtesy of FORD MOTOR CO.
  18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.
    Fig 17: Locating Engine Oil Pressure Switch Electrical Connector
    G06095720Courtesy of FORD MOTOR CO.
  19. Disconnect the LH HO2S electrical connector.
    Fig 18: Locating LH HO2S Electrical Connector
    G06095721Courtesy of FORD MOTOR CO.
  20. Disconnect the 3 LH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 19: Locating LH Coil-On-Plug Electrical Connectors
      G06095722Courtesy of FORD MOTOR CO.
  21. Remove the nut and the B+ wire from the generator.
    Fig 20: Locating Generator Wire Nut
    G06095723Courtesy of FORD MOTOR CO.
  22. Detach the 2 wiring harness retainers.
    • Remove the B+ harness from the engine.
      Fig 21: Locating Wiring Harness Retainers
      G06095724Courtesy of FORD MOTOR CO.
  23. Remove the EGR tube fitting from the EGR valve.
    Fig 22: Locating EGR Tube Fitting
    G06095725Courtesy of FORD MOTOR CO.
  24. Remove the 2 upper intake manifold bracket bolts (1 shown).
    Fig 23: Locating Upper Intake Manifold Bracket Bolts
    G06095726Courtesy of FORD MOTOR CO.
    25. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  25. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gaskets.
      Fig 24: Locating Upper Intake Manifold Bolts
      G06095727Courtesy of FORD MOTOR CO.
  26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 25: Locating Fuel Rail And Injectors Assembly Bolts
    G06095728Courtesy of FORD MOTOR CO.
    27. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  27. Remove the 8 lower intake manifold bolts and the lower intake manifold.
    • Remove and discard the gaskets.
      Fig 26: Locating Lower Intake Manifold Bolts
      G06095729Courtesy of FORD MOTOR CO.
    28. NOTE: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
    NOTE: LH shown, RH similar.
    Fig 27: Locating Coil-On-Plugs With Bolts
    G06095730Courtesy of FORD MOTOR CO.
  28. Remove the 6 bolts and the 6 coil-on-plugs.

    FWD vehicles 

  29. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 28: Locating RH Heated Oxygen Sensor Electrical Connector
    G06095679Courtesy of FORD MOTOR CO.
  30. Remove the 3 bolts and the RH heat shield.
    Fig 29: Locating RH Heat Shield Bolts
    G06095680Courtesy of FORD MOTOR CO.
  31. Remove the 3 nuts and the RH catalytic converter.
    • Discard the nuts and gasket.
      Fig 30: Locating RH Catalytic Converter Nut
      G06095681Courtesy of FORD MOTOR CO.

      All vehicles 

  32. Remove the 6 RH exhaust manifold nuts and the manifold.
    • Discard the nuts and gasket.
      Fig 31: Locating RH Exhaust Manifold Nuts
      G06095734Courtesy of FORD MOTOR CO.
  33. Remove and discard the 6 RH exhaust manifold studs.
    Fig 32: Locating RH Exhaust Manifold Studs
    G06095735Courtesy of FORD MOTOR CO.
  34. Remove the bolt, 2 nuts and the generator.
    Fig 33: Locating Generator Nuts With Bolts
    G06095736Courtesy of FORD MOTOR CO.
  35. Remove the 3 bolts and the A/C compressor bracket.
    Fig 34: Locating A/C Compressor Bracket Bolts
    G06095737Courtesy of FORD MOTOR CO.
  36. Remove the 3 bolts and the LH heat shield.
    Fig 35: Locating LH Heat Shield Bolts
    G06095738Courtesy of FORD MOTOR CO.
  37. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
      Fig 36: Locating Stud Bolt And Oil Level Indicator With Tube
      G06095739Courtesy of FORD MOTOR CO.
  38. Remove the 6 nuts, the LH catalytic converter and the gasket.
    • Discard the gasket and nuts.
      Fig 37: Locating LH Catalytic Converter Nuts
      G06095740Courtesy of FORD MOTOR CO.
  39. Remove and discard the 6 LH exhaust manifold studs.
    Fig 38: Locating LH Exhaust Manifold Studs
    G06095735Courtesy of FORD MOTOR CO.
  40. Remove the EOP switch and, if equipped, the block heater.
    Fig 39: Locating EOP Switch
    G06095742Courtesy of FORD MOTOR CO.
  41. Remove and discard the oil filter.
    Fig 40: Locating Oil Filter
    G06095743Courtesy of FORD MOTOR CO.
  42. Position the Stretchy Belt Remover under the coolant pump belt as shown.
    Fig 41: Positioning Stretchy Belt Remover
    G06095744Courtesy of FORD MOTOR CO.
    43. NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley approximately 90 degrees.
    Fig 42: Identifying Stretchy Belt Remover
    G06095745Courtesy of FORD MOTOR CO.
  43. With the help of an assistant, turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown.
  44. Remove the coolant pump belt.
    • Fold the Stretchy Belt Remover over the top of the coolant pump belt.
    • In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine removing the coolant pump belt.
      Fig 43: Removing Coolant Pump Belt
      G06095746Courtesy of FORD MOTOR CO.
    45. NOTE: Failure to use the correct special tools, assembled as shown in the Fig 44, will result in damage to the coolant pump pulley and/or special tools.
    Fig 44: Removing Coolant Pump Pulley
    G06095568Courtesy of FORD MOTOR CO.
  45. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
  46. Remove the 5 coolant pump housing bolts.
    Fig 45: Identifying Coolant Pump Housing Bolts
    G06095748Courtesy of FORD MOTOR CO.
  47. Loosen the clamp and detach the coolant hose. Remove the coolant pump housing.
    Fig 46: Identifying Coolant Hose Clamp
    G06095749Courtesy of FORD MOTOR CO.
  48. Remove the nut and the radio interference capacitor.
    Fig 47: Locating Radio Interference Capacitor With Nut
    G06095750Courtesy of FORD MOTOR CO.
  49. Remove the bolts and the RH valve cover.
    • Discard the gasket.
      Fig 48: Locating RH Valve Cover With Bolts
      G06095751Courtesy of FORD MOTOR CO.
  50. Remove the bolts and the LH valve cover.
    • Discard the gasket.
      Fig 49: Locating LH Valve Cover With Bolts
      G06095752Courtesy of FORD MOTOR CO.
  51. Remove the 15 bolts and the oil pan.
    • Discard the gasket.
      Fig 50: Locating Oil Pan Bolts
      G06095753Courtesy of FORD MOTOR CO.
  52. Remove the 2 bolts and the oil pump screen and pickup tube.
    Fig 51: Locating Oil Pump Screen And Pickup Tube
    G06095613Courtesy of FORD MOTOR CO.
  53. Remove and discard the O-ring seal.
    Fig 52: Locating O-Ring Seal
    G06095755Courtesy of FORD MOTOR CO.
  54. Remove the oil pan baffle.
    1. Remove the 4 M6 oil pan baffle nuts.
    2. Remove the 4 M8 oil pan baffle nuts.
      Fig 53: Identifying Oil Pan Baffle Nuts
      G06095615Courtesy of FORD MOTOR CO.
  55. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 54: Locating Accessory Drive Belt Tensioner With Bolts
    G06095757Courtesy of FORD MOTOR CO.
  56. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
      Fig 55: Locating Crankshaft Pulley Bolt
      G06095758Courtesy of FORD MOTOR CO.
  57. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 56: Removing Crankshaft Pulley
    G06095503Courtesy of FORD MOTOR CO.
  58. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 57: Removing Discard Crankshaft Front Seal
    G06095509Courtesy of FORD MOTOR CO.
    59. NOTE: Note the position of the alignment dowel on the engine front cover.
    Fig 58: Locating LH VCT Connector With Bolts
    G06095761Courtesy of FORD MOTOR CO.
  59. Remove the 2 bolts and the LH VCT.
    60. NOTE: Note the position of the alignment dowel on the engine front cover.
    Fig 59: Locating RH VCT With Bolts
    G06095762Courtesy of FORD MOTOR CO.
  60. Remove the 2 bolts and the RH VCT.
    61. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
    NOTE: Note the location of all bolts and stud bolts for installation.
  61. Remove the 14 bolts, 2 stud bolts and the engine front cover.
    • Discard the gaskets.
      Fig 60: Identifying Engine Front Cover And Stud Bolts
      G06095763Courtesy of FORD MOTOR CO.
    62. NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
    NOTE: LH shown, RH similar.
    Fig 61: Locating Spark Plugs
    G06095764Courtesy of FORD MOTOR CO.
  62. Remove the LH and RH spark plugs.
    63. NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" (orange in color).
    Fig 62: Locating Ignition Pulse Wheel
    G06095525Courtesy of FORD MOTOR CO.
  63. Remove the ignition pulse wheel.
  64. Install the crankshaft pulley bolt and washer.
    Fig 63: Locating Crankshaft Pulley Bolt
    G06095526Courtesy of FORD MOTOR CO.
  65. Rotate the crankshaft clockwise to position the crankshaft key way in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead Center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
      Fig 64: Identifying Timing Mark Location
      G06095527Courtesy of FORD MOTOR CO.
  66. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
    Fig 65: Locating Crankshaft Key Way
    G06095528Courtesy of FORD MOTOR CO.
  67. Verify that the RH camshafts are in the neutral position.
    Fig 66: Identifying Timing Mark On RH Camshafts
    G06095529Courtesy of FORD MOTOR CO.
  68. Remove the RH timing chain tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
      Fig 67: Identifying RH Timing Chain Tensioner Arm With Bolts
      G06095530Courtesy of FORD MOTOR CO.
  69. Remove the 2 bolts and the RH timing chain guide.
    • Remove the RH timing chain from the engine.
      Fig 68: Locating RH Timing Chain Guide And Bolts
      G06095531Courtesy of FORD MOTOR CO.
  70. Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    Fig 69: Locating Crankcase Keyway
    G06095532Courtesy of FORD MOTOR CO.
  71. Verify the LH camshafts are in the neutral position.
    Fig 70: Identifying Timing Mark On LH Camshafts
    G06095533Courtesy of FORD MOTOR CO.
  72. Remove the LH timing chain and tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
      Fig 71: Identifying LH Timing Chain And Tensioner Arm With Bolts
      G06095534Courtesy of FORD MOTOR CO.
  73. Remove the 2 bolts and the LH timing chain guide.
    • Remove the LH timing chain from the engine.
      Fig 72: Locating LH Timing Chain Guide With Bolts
      G06095535Courtesy of FORD MOTOR CO.
  74. Remove the crankshaft pulley bolt and the crankshaft sprocket.
    Fig 73: Locating Crankshaft Pulley Bolt And Crankshaft Sprocket
    G06095536Courtesy of FORD MOTOR CO.
  75. Remove the 4 bolts in the sequence shown.
    • Remove the oil pump.
      Fig 74: Identifying Oil Pump Bolts
      G06095777Courtesy of FORD MOTOR CO.
    76. NOTE: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
    Fig 75: Removing Camshaft Oil Seal
    G06095569Courtesy of FORD MOTOR CO.
  76. Using the Oil Seal Remover, remove the camshaft oil seal and discard.
  77. Remove the 2 bolts and the camshaft oil seal retainer.
    • Discard the press-in-place gasket.
      Fig 76: Locating Camshaft Oil Seal Retainer With Bolts
      G06095779Courtesy of FORD MOTOR CO.
    78. NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
    Fig 77: Identifying Timing Mark On LH Camshafts
    G06095571Courtesy of FORD MOTOR CO.
  78. Verify the LH camshafts are in the neutral position.
    79. NOTE: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket 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 removal of the camshaft phaser and sprocket bolts.
    Fig 78: Removing LH Camshaft Phaser And Sprocket Bolts
    G06095556Courtesy of FORD MOTOR CO.
  79. Remove the 3 bolts and the LH camshaft phaser and sprocket.
  80. Remove and discard the VCT system oil filter screen from the LH camshaft.
    Fig 79: Locating Oil Filter Screen
    G06095782Courtesy of FORD MOTOR CO.
    81. NOTE: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in Fig 80). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
    Fig 80: Locating Cylinder Head Camshaft Bearing Caps
    G06095573Courtesy of FORD MOTOR CO.
  81. If necessary, mark the camshaft bearing cap position and orientation as shown in the Fig 80.
    82. NOTE: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 5L) first, or damage to the thrust caps may occur.
    NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
  82. Loosen the bolts evenly in the sequence shown.
    1. Remove the camshaft bearing thrust caps (1L and 5L).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.
      Fig 81: Identifying Camshaft Bearing Cap Bolts
      G06095574Courtesy of FORD MOTOR CO.
    83. NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
    Fig 82: Locating RH Camshafts Timing Mark Location
    G06095545Courtesy of FORD MOTOR CO.
  83. Verify the RH camshafts are in the neutral position.
    84. NOTE: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket 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 removal of the camshaft phaser and sprocket bolts.
    Fig 83: Locating RH Camshaft Phaser And Sprocket Bolts
    G06095557Courtesy of FORD MOTOR CO.
  84. Remove the 3 bolts and the RH camshaft phaser and sprocket.
  85. Remove and discard the VCT system oil filter screen from the RH camshaft.
    Fig 84: Locating Camshaft Phaser And Sprocket
    G06095558Courtesy of FORD MOTOR CO.
    86. NOTE: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in Fig 85). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
    Fig 85: Locating Camshaft Bearing Cap
    G06095586Courtesy of FORD MOTOR CO.
  86. If necessary, mark the camshaft bearing cap position and orientation as shown in the Fig 85.
    87. NOTE: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (5R and 1R) first, or damage to the thrust caps may occur.
    NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
  87. Loosen the bolts evenly in the sequence shown.
    1. Remove the camshaft bearing thrust caps (5R and 1R).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.
      Fig 86: Identifying Camshaft Bearing Caps Bolts
      G06095587Courtesy of FORD MOTOR CO.
    88. NOTE: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    NOTE: RH shown, LH similar.
  88. Remove the LH and RH camshaft roller followers.
    • Mark the location of the roller followers, using a permanent-type marker.
      Fig 87: Locating Roller Followers
      G06095790Courtesy of FORD MOTOR CO.
    89. NOTE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
  89. Remove the hydraulic lash adjusters.
    90. NOTE: RH shown, LH similar.
  90. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the bolts and the gaskets.
      Fig 88: Identifying Cylinder Heads Bolts
      G06095791Courtesy of FORD MOTOR CO.
    91. 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.
  91. Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
  92. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  93. Remove the bolts and the oil separator cover.
    • Discard the gasket.
      Fig 89: Locating Oil Separator Cover Bolts
      G06095792Courtesy of FORD MOTOR CO.
  94. Remove the crankshaft key.
    Fig 90: Locating Crankshaft Key
    G06095793Courtesy of FORD MOTOR CO.
  95. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer' s instructions.
    96. NOTE: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
  96. Remove the connecting rod cap bolts and cap.
    • Discard the connecting rod cap bolts.
      Fig 91: Locating Connecting Rod Cap Bolts
      G06095794Courtesy of FORD MOTOR CO.
    97. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
  97. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
    • Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.
      Fig 92: Removing Piston/Rod Assembly
      G06095795Courtesy of FORD MOTOR CO.
  98. Remove the engine block from the stand and place on a workbench.
  99. Remove the bolts and studs in the indicated sequence.
    • Discard the lower cylinder block bolts.
    • Remove the lower cylinder block.
      Fig 93: Identifying Lower Cylinder Block Bolts
      G06095796Courtesy of FORD MOTOR CO.
  100. Remove the crankshaft rear main seal.
    • Remove the crankshaft.
      Fig 94: Locating Crankshaft Rear Main Seal
      G06095797Courtesy of FORD MOTOR CO.
  101. Remove the crankshaft thrust bearing from the cylinder block.
    Fig 95: Locating Crankshaft Thrust Bearing
    G06095798Courtesy of FORD MOTOR CO.
    102. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
    Fig 96: Identifying Main Bearings Installation Position
    G06095799Courtesy of FORD MOTOR CO.
  102. Remove the bearings from the lower cylinder block.
    103. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
    Fig 97: Identifying Crankshaft Main Bearings Installation Position
    G06095800Courtesy of FORD MOTOR CO.
  103. Remove the crankshaft main bearings from the cylinder block.
  104. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .


MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Metal Surface Prep ZC-31-A -
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

Lower Engine Block (View 1) 

Fig 1: Exploded View Of Lower Engine Block (View 1)
G06095825Courtesy of FORD MOTOR CO.
PART NUMBER DESCRIPTION

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 6M256 RH timing chain guide
6 6306 Crankshaft sprocket
7 6L266 LH timing chain tensioner
8 6K255 LH timing chain tensioner arm
9 6268 LH timing chain
10 6B297 LH timing chain guide
11 6621 Oil pump
12 W701923 Cup plug
13 6B752 Oil separator gasket
14 6869 Oil separator cover
15 8A505 Water inlet tube
16 6701 Crankshaft rear oil seal
17 6A373 Spacer plate
18 6375 Flexplate
19 9278 Engine Oil Pressure (EOP) switch
20 W701528 Woodruff key
21 6622 Oil pickup tube and screen
22 6687 Oil pan baffle
23 6714 Oil filter
24 6675 Oil pan
25 10300 Generator
26 6B209 Accessory drive belt tensioner
27 6700 Crankshaft front seal
28 6316 Crankshaft vibration damper
29 N806165 Crankshaft vibration damper washer
30 W701512 Crankshaft vibration damper bolt
31 6C315 Crankshaft Position (CKP) sensor
32 12K073 Camshaft Position (CMP) sensor (2 required)
33 6M280 Variable Camshaft Timing (VCT) solenoid (2 required)
34 6019 Front cover

Lower Engine Block (View 2) 

Fig 2: Exploded View Of Lower Engine Block (View 2)
G06095826Courtesy of FORD MOTOR CO.
PART NUMBER DESCRIPTION

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

Cylinder Heads and Intake Manifolds 

Fig 3: Exploded View Of Cylinder Heads And Intake Manifolds
G06095827Courtesy of FORD MOTOR CO.
PART NUMBER DESCRIPTION

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 12029 Coil-on-plug (6 required)
6 6A505 LH valve cover
7 9F792 Fuel rail
8 9F593 Fuel injector (6 required)
9 9424 Lower intake manifold
10 6B280 Camshaft thrust bearing cap
11 6B280 Camshaft bearing cap
12 6C683 LH Variable Camshaft Timing (VCT) system oil filter
13 6A267 LH intake camshaft
14 6C524 LH camshaft phaser and sprocket
15 6A269 LH exhaust camshaft
16 6B295 Camshaft oil seal retainer gasket
17 6B293 Camshaft oil seal retainer
18 - Camshaft oil seal
19 6A359 Coolant pump drive pulley
20 6050 LH cylinder head
21 12405 Spark plug (6 required)
22 6C501 Hydraulic lash adjuster (24 required)
23 6513 Valve spring (24 required)
24 6529 Camshaft roller follower (24 required)
25 8501 Coolant pump housing
26 8K453 Coolant pump belt
27 6518 Valve spring retainer key (48 required)
28 6514 Valve spring retainer (24 required)
29 6A517 Valve stem seal (24 required)
30 - Oil level indicator
31 6754 Oil level indicator tube
32 6083 LH cylinder head gasket
33 6507 Intake valve (24 required)
34 6505 Exhaust valve (24 required)
35 6051 RH cylinder head gasket
36 6050 RH cylinder head
37 6C524 RH camshaft phaser and sprocket
38 6C683 RH VCT system oil filter
39 6A266 RH intake camshaft
40 6A268 RH exhaust camshaft
41 6A268 Camshaft thrust bearing cap
42 6A258 Camshaft bearing cap
NOTE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: If 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 .

All vehicles 

    NOTE: This procedure is for selecting bearings using a new crankshaft.
  1. 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: Locating Codes
        G06095828Courtesy of FORD MOTOR CO.
  2. Using the chart, 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 Chart
      G06095829Courtesy of FORD MOTOR CO.
    3. 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 Lower Main Bearings
    G06095800Courtesy of FORD MOTOR CO.
  3. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
  4. 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 On Lower Cylinder Block
    G06095799Courtesy of FORD MOTOR CO.
  5. Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.
    Fig 8: Locating Crankshaft Thrust Bearing
    G06095798Courtesy of FORD MOTOR CO.
  6. Install the crankshaft key.
    Fig 9: Locating Crankshaft Key
    G06095793Courtesy of FORD MOTOR CO.
  7. Apply clean engine oil to the crankshaft main and rod bearing journals.
  8. Position the crankshaft in the cylinder block.
    Fig 10: Positioning Crankshaft In Cylinder Block
    G06095834Courtesy of FORD MOTOR CO.
    9. 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 And Sealant To Cylinder Block
    G06095835Courtesy of FORD MOTOR CO.
  9. Apply gasket and sealant to the cylinder block as shown.
    10. 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.
  10. 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).
      Fig 12: Identifying Lower Cylinder Block Bolts Tightening Sequence
      G06095836Courtesy of FORD MOTOR CO.
  11. 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
      G06095267Courtesy of FORD MOTOR CO.
  12. 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 Rear Main Oil Seal
    G06095838Courtesy of FORD MOTOR CO.
  13. Install the engine-to-transaxle separator plate.
    Fig 15: Locating Engine-To-Transaxle Separator Plate
    G06095705Courtesy of FORD MOTOR CO.
  14. Position the flexplate and install the bolts.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 16: Locating Flexplate Bolts
      G06095704Courtesy of FORD MOTOR CO.
  15. Mount the engine on an engine stand.
  16. Using the chart, 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 Chart
      G06100302Courtesy of FORD MOTOR CO.
    17. 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 DISASSEMBLY AND ASSEMBLY  of Subassemblies - Piston.
    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: Identifying Piston Ring Compressor And Connecting Rod Installer
    G06095841Courtesy of FORD MOTOR CO.
  17. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
    18. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
  18. 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).
      Fig 19: Locating Connecting Rod Cap Bolts
      G06095794Courtesy of FORD MOTOR CO.
  19. Install the crankcase cover, a new gasket and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 20: Locating Oil Separator Cover Bolts
      G06095792Courtesy of FORD MOTOR CO.
    20. NOTE: LH shown, RH similar.
  20. Position the new LH and RH cylinder heads and gaskets. 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 LH And RH Cylinder Heads Bolts Tightening Sequence
      G06095844Courtesy of FORD MOTOR CO.
  21. Install the crankshaft pulley bolt and rotate the crankshaft key way to the 11 o'clock position to locate Top Dead Center (TDC).
    Fig 22: Locating Crankshaft Pulley Bolt
    G06095845Courtesy of FORD MOTOR CO.
    22. NOTE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
  22. Install the hydraulic lash adjusters.
    • Lubricate the hydraulic lash adjusters with clean engine oil.
  23. Apply clean engine oil to the LH and RH camshaft roller followers.
    24. NOTE: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    NOTE: RH shown, LH similar.
    Fig 23: Locating Roller Followers
    G06095790Courtesy of FORD MOTOR CO.
  24. Install the LH and RH camshaft roller followers.
    25. NOTE: LH shown, RH similar.
    Fig 24: Locating Oil Filter Screen
    G06095782Courtesy of FORD MOTOR CO.
  25. Install the new LH and RH oil filter screens in the intake camshafts.
  26. Position the camshaft phaser and sprockets onto the intake camshafts.
    • Install the 3 bolts finger-tight.
  27. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
    • Align the LH camshafts as shown.
      Fig 25: Identifying Timing Mark On LH Camshafts
      G06095848Courtesy of FORD MOTOR CO.
    28. NOTE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    NOTE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
  28. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
    • Loosely install the bolts.
      Fig 26: Locating LH Camshaft Bearing Caps
      G06095576Courtesy of FORD MOTOR CO.
  29. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
    • Loosely install the bolts.
      Fig 27: Locating Bearing Thrust Caps
      G06095577Courtesy of FORD MOTOR CO.
    30. NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
  30. Tighten the LH camshaft bearing cap bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
      Fig 28: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
      G06095578Courtesy of FORD MOTOR CO.
    31. NOTE: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts 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 camshaft phaser and sprocket bolts.
    Fig 29: Tightening LH Camshaft Phaser And Sprocket Bolts
    G06095556Courtesy of FORD MOTOR CO.
  31. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
    32. NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
  32. Install the camshaft oil seal retainer and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 30: Locating Camshaft Oil Seal Retainer With Bolts
      G06095779Courtesy of FORD MOTOR CO.
    33. NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
    Fig 31: Installing Camshaft Oil Seal
    G06095581Courtesy of FORD MOTOR CO.
  33. Using the Power Steering Pump Pulley Installer, Camshaft Oil Seal Installer and the Camshaft Oil Seal Protector, install a new camshaft oil seal.
  34. Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
    • Align the RH camshafts as shown.
      Fig 32: Identifying Timing Mark On RH Camshafts
      G06095855Courtesy of FORD MOTOR CO.
    35. NOTE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    NOTE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed or damage to the thrust caps can occur.
    NOTE: Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil.
  35. Install the camshaft bearing caps.
    • Loosely install the bolts.
      Fig 33: Locating Camshaft Bearing Caps Bolts
      G06095589Courtesy of FORD MOTOR CO.
    36. NOTE: Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil.
  36. Install the camshaft bearing thrust caps.
    • Loosely install the bolts.
      Fig 34: Locating Camshaft Bearing Thrust Caps
      G06095590Courtesy of FORD MOTOR CO.
    37. NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
  37. Tighten the RH camshaft bearing cap bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
      Fig 35: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
      G06095591Courtesy of FORD MOTOR CO.
    38. NOTE: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts 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 camshaft phaser and sprocket bolts.
    Fig 36: Locating RH Camshaft Phaser And Sprocket Bolts
    G06095557Courtesy of FORD MOTOR CO.
  38. Tighten the 3 RH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
  39. Position the oil pump and install the bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
      Fig 37: Tightening Oil Pump Bolts
      G06095617Courtesy of FORD MOTOR CO.
  40. Remove the crankshaft pulley bolt.
    Fig 38: Locating Crankshaft Pulley Bolt
    G06095845Courtesy of FORD MOTOR CO.
    41. NOTE: Failure to verify correct timing drive component alignment will result in severe engine damage.
    Fig 39: Locating Crankshaft Sprocket Timing Mark Location
    G06095862Courtesy of FORD MOTOR CO.
  41. Install the crankshaft sprocket with the timing mark facing out. The timing mark on the LH and RH timing chains will be aligned to this mark during assembly.
    42. NOTE: LH shown, RH similar.
    Fig 40: Positioning Chain Tensioner In Soft-Jawed Vise
    G06095538Courtesy of FORD MOTOR CO.
  42. Position the chain tensioner in a soft-jawed vise.
    43. NOTE: LH shown, RH similar.
    Fig 41: Holding Chain Tensioner Ratchet Lock Mechanism Away
    G06095539Courtesy of FORD MOTOR CO.
  43. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
    44. 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.
  44. Slowly compress the timing chain tensioner.
  45. Retain the tensioner piston with a 1.5 mm (0.06 in) diameter wire or paper clip.
    Fig 42: Identifying Timing Mark On RH Camshafts
    G06095540Courtesy of FORD MOTOR CO.
  46. 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 29 links and mark the link.
    3. Continue counting to link 42 and mark the link.
      Fig 43: Identifying Timing Marks On LH And RH Timing Chains
      G06095541Courtesy of FORD MOTOR CO.
  47. Position the LH timing chain and guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
      Fig 44: Locating LH Timing Chain Guide With Bolts
      G06095535Courtesy of FORD MOTOR CO.
  48. 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 bolts.
      • Tighten to 25 Nm (18 lb-ft).
        Fig 45: Identifying LH Timing Chain Tensioner Arm And Bolts
        G06095543Courtesy of FORD MOTOR CO.
  49. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
    Fig 46: Locating Crankshaft Keyway
    G06095544Courtesy of FORD MOTOR CO.
  50. Verify that the RH camshafts are correctly positioned.
    Fig 47: Locating RH Camshafts Timing Mark Location
    G06095545Courtesy of FORD MOTOR CO.
  51. Install the RH timing chain and chain guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
      Fig 48: Locating RH Timing Chain Guide And Bolts
      G06095531Courtesy of FORD MOTOR CO.
  52. Install the RH timing chain tensioner and tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
      • Tighten to 25 Nm (18 lb-ft).
        Fig 49: Identifying RH Timing Chain Tensioner And Tensioner Arm
        G06095547Courtesy of FORD MOTOR CO.
  53. Remove the LH and RH timing chain tensioner piston retaining wires.
  54. Rotate the crankshaft counterclockwise 120 degrees to TDC.
    55. NOTE: Failure to verify correct timing drive component alignment will result in severe engine damage.
  55. 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 50: Identifying Chain Links Between Camshaft And Crankshaft Timing Marks Location
      G06095873Courtesy of FORD MOTOR CO.
  56. Remove the crankshaft pulley bolt and washer.
    Fig 51: Locating Crankshaft Pulley Bolt
    G06095526Courtesy of FORD MOTOR CO.
    57. 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).
    Fig 52: Locating Ignition Pulse Wheel
    G06095525Courtesy of FORD MOTOR CO.
  57. Install the ignition pulse wheel.
    58. NOTE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
  58. Install the LH and RH spark plugs.
    • Tighten to 15 Nm (133 lb-in).
      Fig 53: Locating Spark Plugs
      G06095876Courtesy of FORD MOTOR CO.
    59. 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.
    NOTE: Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder block-to-oil pan joint.
  59. Use a plastic scraping tool to remove all traces of sealant.
    • Clean all sealing surfaces with metal surface prep and install new gaskets.
    60. NOTE: Clean and degrease 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.
    Fig 54: Identifying Silicone Gasket Applying Area
    G06095523Courtesy of FORD MOTOR CO.
  60. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
    61. NOTE: Fasteners 4 and 13 are stud bolts.
  61. Position the front cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 25 Nm (18 lb-ft).
      Fig 55: Identifying Front Cover Bolts
      G06095524Courtesy of FORD MOTOR CO.
    62. NOTE: Note the position of the alignment dowel on the engine front cover.
  62. Install the 2 bolts and the LH Variable Camshaft Timing (VCT) solenoid.
    • Tighten to 10 Nm (89 lb-in).
      Fig 56: Locating LH VCT Connector With Bolts
      G06095761Courtesy of FORD MOTOR CO.
    63. NOTE: Note the position of the alignment dowel on the engine front cover.
  63. Install the 2 bolts and the RH VCT solenoid.
    • Tighten to 10 Nm (89 lb-in).
      Fig 57: Locating RH VCT With Bolts
      G06095762Courtesy of FORD MOTOR CO.
    64. NOTE: Clean all sealing surfaces with metal surface prep.
  64. Apply clean engine oil to the seal lip and seal bore before installing the seal.
  65. Using the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
    Fig 58: Installing Crankshaft Front Seal
    G06095881Courtesy of FORD MOTOR CO.
    66. NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant.
    NOTE: Sealing surfaces must be free of dirt and oil.
    NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of sealant application.
    Fig 59: Applying Silicone Gasket And Sealant To End Of Crankshaft Pulley Keyway Slot
    G06095504Courtesy of FORD MOTOR CO.
  66. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
    67. NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
    Fig 60: Tightening Crankshaft Pulley Nut
    G06095883Courtesy of FORD MOTOR CO.
  67. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
  68. Install the bolt and washer. 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 61: Locating Crankshaft Pulley Bolt
      G06095758Courtesy of FORD MOTOR CO.
  69. Install the belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 62: Locating Accessory Drive Belt Tensioner With Bolts
      G06095757Courtesy of FORD MOTOR CO.
  70. Install the 8 nuts and the oil pan baffle in the following sequence.
    1. Tighten the 4 M6 oil pan baffle nuts in 2 stages.
      • Stage 1: Tighten to 5 Nm (44 lb-in).
      • Stage 2: Tighten an additional 45 degrees.
    2. Then install and tighten the 4 M8 oil pan baffle nuts in 2 stages.
      • Stage 1: Tighten to 15 Nm (133 lb-in).
      • Stage 2: Tighten an additional 45 degrees.
        Fig 63: Identifying Oil Pan Baffle Nuts
        G06095615Courtesy of FORD MOTOR CO.
  71. Install a new O-ring seal on the oil pump screen and pickup tube.
    • Lubricate the O-ring seal with clean engine oil.
      Fig 64: Locating O-Ring Seal
      G06095755Courtesy of FORD MOTOR CO.
  72. Install the oil pump screen and pickup tube.
    1. Position the oil pump screen and pickup tube.
    2. Install the 2 bolts and tighten to 10 Nm (89 lb-in).
      Fig 65: Positioning Oil Pump Screen And Pickup Tube
      G06095614Courtesy of FORD MOTOR CO.
    73. NOTE: The valve cover must be installed and the bolts and studs 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.
    Fig 66: Identifying Sealant Applying Area
    G06095889Courtesy of FORD MOTOR CO.
  73. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface and the cam seal retainer-to-cylinder head joints.
    74. NOTE: Install a new valve cover gasket.
  74. Position the LH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
      Fig 67: Identifying LH Valve Cover Bolts Tightening Sequence
      G06095494Courtesy of FORD MOTOR CO.
    75. NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.
    Fig 68: Identifying Sealant Applying Area
    G06095891Courtesy of FORD MOTOR CO.
  75. Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
    76. NOTE: Install a new valve cover gasket.
  76. Position the RH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
      Fig 69: Identifying Valve Cover Bolts Tightening Sequence
      G06095498Courtesy of FORD MOTOR CO.
  77. Install the radio interference capacitor and the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 70: Locating Radio Interference Capacitor With Nut
      G06095750Courtesy of FORD MOTOR CO.
  78. Position the coolant pump housing and attach the coolant hose.
    • Tighten the clamp to 7 Nm (62 lb-in).
      Fig 71: Locating Coolant Hose Clamp
      G06095894Courtesy of FORD MOTOR CO.
  79. Install the 5 coolant pump housing bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 72: Locating Coolant Pump Housing Bolts
      G06095748Courtesy of FORD MOTOR CO.
    80. NOTE: Failure to use the correct special tools, assembled as shown in the Fig 73, will result in damage to the coolant pump pulley and/or special tools.
  80. Install the Camshaft Pulley Installer in the camshaft as shown in the Fig 73.
    • Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
      Fig 73: Identifying Camshaft Pulley Installer Screw
      G06095896Courtesy of FORD MOTOR CO.
    81. NOTE: Failure to use the correct special tools, assembled as shown in the Fig 74, 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 Camshaft Pulley Installer (303-458).
  81. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the Fig 74.
    • Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
      Fig 74: Identifying Camshaft Pulley Installer, Power Steering Pump Pulley Installer And Water Pump Pulley Spacer
      G06095583Courtesy of FORD MOTOR CO.
  82. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
    Fig 75: Locating Coolant Pump Belt
    G06095898Courtesy of FORD MOTOR CO.
    83. NOTE: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.
  83. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
  84. Lubricate the O-ring seal with clean engine oil and install the oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      Fig 76: Locating Oil Filter
      G06095743Courtesy of FORD MOTOR CO.
  85. Install the Engine Oil Pressure (EOP) switch and, if equipped, the block heater.
    • Tighten the EOP switch to 14 Nm (124 lb-in).
    • Tighten the block heater to 21 Nm (15 lb-ft).
      Fig 77: Locating EOP Switch
      G06095742Courtesy of FORD MOTOR CO.
  86. Install 6 new LH catalytic converter studs.
    • Tighten to 12 Nm (106 lb-in).
      Fig 78: Locating LH Exhaust Manifold Studs
      G06095735Courtesy of FORD MOTOR CO.
  87. Install a new gasket and the LH catalytic converter and 6 new nuts.
    • Tighten in the sequence shown to 20 Nm (177 lb-in).
      Fig 79: Identifying LH Catalytic Converter Nut Tightening Sequence
      G06095902Courtesy of FORD MOTOR CO.
  88. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
    Fig 80: Identifying O-Ring On Oil Level Indicator Tube
    G06095903Courtesy of FORD MOTOR CO.
  89. Position the oil level indicator and tube and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 81: Identifying Oil Level Indicator And Tube With Stud Bolt
      G06095739Courtesy of FORD MOTOR CO.
  90. Install the 3 bolts and the LH heat shield.
    • Tighten to 10 Nm (89 lb-in).
      Fig 82: Locating LH Heat Shield Bolts
      G06095738Courtesy of FORD MOTOR CO.
  91. Install the 3 bolts and the A/C compressor bracket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 83: Locating A/C Compressor Bracket Bolts
      G06095737Courtesy of FORD MOTOR CO.
  92. Position the generator and install the bolt and 2 nuts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 84: Locating Generator Nuts With Bolts
      G06095736Courtesy of FORD MOTOR CO.
  93. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
      Fig 85: Locating LH Exhaust Manifold Studs
      G06095735Courtesy of FORD MOTOR CO.
  94. Install a new gasket and the RH exhaust manifold and new nuts.
    • Tighten the nuts in 2 stages in the sequence shown.
      • Stage 1: Tighten to 20 Nm (177 lb-in).
      • Stage 2: Tighten to 20 Nm (177 lb-in).
        Fig 86: Identifying Exhaust Manifold Bolts Tightening Sequence
        G06095622Courtesy of FORD MOTOR CO.

        FWD vehicles 

  95. Install a new gasket and the RH catalytic converter and the 3 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 87: Locating RH Catalytic Converter Nut
      G06095681Courtesy of FORD MOTOR CO.
  96. Install the 3 bolts and the RH heat shield.
    • Tighten to 10 Nm (89 lb-in).
      Fig 88: Locating RH Heat Shield Bolts
      G06095680Courtesy of FORD MOTOR CO.
  97. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 89: Locating RH Heated Oxygen Sensor Electrical Connector
    G06095679Courtesy of FORD MOTOR CO.

    All vehicles 

    98. NOTE: LH shown, RH similar.
  98. 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 6 coil-on-plugs and the bolts.

    • Tighten to 6 Nm (53 lb-in).
      Fig 90: Locating Coil-On-Plugs With Bolts
      G06095730Courtesy of FORD MOTOR CO.
    99. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
  99. Position the lower intake manifold and install the 8 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
      Fig 91: Identifying Lower Intake Manifold Bolts Tightening Sequence
      G06095489Courtesy of FORD MOTOR CO.
    100. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
  100. Install new fuel injector O-rings.
    • Separate the fuel injectors from the fuel rail.
    • Remove and discard the fuel injector O-rings.
    • Install new O-rings and lubricate with clean engine oil.
    • Install the fuel injectors onto the fuel rail.
      Fig 92: Locating Fuel Injectors O-Rings
      G06095340Courtesy of FORD MOTOR CO.
  101. Install the 4 bolts and the fuel rail and injectors assembly.
    • Tighten to 10 Nm (89 lb-in).
      Fig 93: Locating Fuel Rail And Injectors Assembly Bolts
      G06095728Courtesy of FORD MOTOR CO.
    102. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
  102. Position the upper intake manifold and install the 7 bolts.
    • Tighten the bolts in 2 stages in the sequence shown.
      • Stage 1: Tighten to 10 Nm (89 lb-in).
      • Stage 2: Tighten an additional 45 degrees.
        Fig 94: Identifying Upper Intake Manifold Bolts Tightening Sequence
        G06095487Courtesy of FORD MOTOR CO.
  103. Loosen the upper intake manifold bracket lower bolt. Install the upper bolts (1 shown), then tighten all the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 95: Locating Upper Intake Manifold Bracket Bolts
      G06095726Courtesy of FORD MOTOR CO.
  104. Install the EGR tube fitting in the EGR valve.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 96: Locating EGR Tube Fitting
      G06095725Courtesy of FORD MOTOR CO.
  105. Position and attach the 3 B+ wiring harness retainers.
    Fig 97: Locating Wiring Harness Retainers
    G06095724Courtesy of FORD MOTOR CO.
  106. Install the B+ wire and nut on the generator.
    • Tighten to 8 Nm (71 lb-in).
      Fig 98: Locating Generator Wire Nut
      G06095723Courtesy of FORD MOTOR CO.
  107. Connect the 3 LH coil-on-plug electrical connectors.
    • Attach the 2 wiring harness retainers.
      Fig 99: Locating LH Coil-On-Plug Electrical Connectors
      G06095722Courtesy of FORD MOTOR CO.
  108. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 100: Locating LH HO2S Electrical Connector
    G06095721Courtesy of FORD MOTOR CO.
  109. Connect the Engine Oil Pressure (EOP) switch electrical connector and attach the wiring retainer.
    Fig 101: Locating Engine Oil Pressure Switch Electrical Connector
    G06095720Courtesy of FORD MOTOR CO.
  110. Connect the LH VCT electrical connector.
    Fig 102: Locating LH VCT Electrical Connector
    G06095719Courtesy of FORD MOTOR CO.
  111. Connect the fuel injector wiring harness electrical connector.
    Fig 103: Locating Fuel Injector Wiring Harness Electrical Connector
    G06095718Courtesy of FORD MOTOR CO.
  112. Connect the 2 Camshaft Position (CMP) sensor electrical connectors and attach the wiring harness retainer from the engine front cover stud bolt.
    Fig 104: Locating Camshaft Position Sensor Electrical Connectors
    G06095717Courtesy of FORD MOTOR CO.
  113. Connect the Crankshaft Position (CKP) sensor electrical connector and attach the 2 wiring harness retainers.
    Fig 105: Locating Crankshaft Position Sensor Electrical Connector
    G06095716Courtesy of FORD MOTOR CO.
  114. Connect the RH VCT electrical connector.
    Fig 106: Locating RH Variable Camshaft Timing Electrical Connector
    G06095715Courtesy of FORD MOTOR CO.
  115. Connect the RH coil-on-plug electrical connectors.
    • Attach the 2 wiring harness retainers.
      Fig 107: Locating RH Coil-On-Plug Electrical Connectors
      G06095713Courtesy of FORD MOTOR CO.

      FWD vehicles 

  116. Connect the RH HO2S electrical connector.
    Fig 108: Locating RH HO2S Electrical Connector
    G06095931Courtesy of FORD MOTOR CO.

    All vehicles 

  117. Connect the Manifold Absolute Pressure (MAP) electrical connector and attach the wiring retainer.
    Fig 109: Locating Manifold Absolute Pressure Electrical Connector
    G06095712Courtesy of FORD MOTOR CO.
  118. Attach the wiring harness retainer to the upper intake manifold.
    Fig 110: Locating Wiring Harness Retainer
    G06095933Courtesy of FORD MOTOR CO.
  119. Connect the EGR regulator electrical connector and attach the wiring retainer.
    Fig 111: Locating EGR Regulator Electrical Connector
    G06095710Courtesy of FORD MOTOR CO.
  120. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 112: Identifying Engine Oil Pressure Switch
    G06095935Courtesy of FORD MOTOR CO.
  121. Connect the electronic throttle control electrical connector.
    Fig 113: Locating Electronic Throttle Control Electrical Connector
    G06095708Courtesy of FORD MOTOR CO.
  122. Connect the engine block Knock Sensor (KS) electrical connector and attach the wire harness retainer, connect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
    Fig 114: Locating Engine Block Knock Sensor Electrical Connector
    G06095707Courtesy of FORD MOTOR CO.
  123. Using the Spreader Bar and the Engine Lifting Brackets, remove the engine from the engine stand.
    Fig 115: Lifting Engine From Engine Stand
    G06095938Courtesy of FORD MOTOR CO.
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