Disassembly And Assembly: Engine: Material

Lower Engine Block (View 1) 

Fig 1: Exploded View Of Lower Engine Block

Courtesy of FORD MOTOR CO.

Lower Engine Block (View 2) 

Fig 2: Exploded View Of Lower Engine Block

Courtesy of FORD MOTOR CO.

Front Engine Block 

Fig 3: Exploded View Of Front Engine Block

Courtesy of FORD MOTOR CO.

Cylinder Head 

Fig 4: Exploded View Of Cylinder Head

Courtesy of FORD MOTOR CO.

Intake Manifold 

Fig 5: Exploded View Of Intake Manifold

Courtesy of FORD MOTOR CO.

NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.
NOTE: The front bulkhead does not have an oil squirter.
1. Install the 4 oil squirters.
   • Tighten to 4 Nm (35 lb-in).
     Fig 6: Locating Oil Squirters

     Courtesy of FORD MOTOR CO.
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
   Fig 7: Measuring Crankshaft Main Bearing Journal Diameters In At Least Two Directions

   Courtesy of FORD MOTOR CO.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
   Fig 8: Locating Main Bearing Beam

   Courtesy of FORD MOTOR CO.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
   • Tighten the bolts in the sequence shown in 3 stages.
   • Stage 1: Tighten to 5 Nm (44 lb-in).
   • Stage 2: Tighten to 25 Nm (18 lb-ft).
   • Stage 3: Tighten an additional 90 degrees.
     Fig 9: Identifying Main Bearing Beam Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
5. Measure each crankshaft block main bearing bore diameter.
   • Remove the bolts and the main bearing beam.
   • Discard the main bearing beam bolts.
     Fig 10: Measuring Crankshaft Block Main Bearing Bore Diameter

     Courtesy of FORD MOTOR CO.
6. Using the chart, select the crankshaft main bearings.
   Fig 11: Crankshaft Main Bearings Selection Chart

   Courtesy of FORD MOTOR CO.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts.
   • Tighten the bolts in 2 stages.
   • Stage 1: Tighten to 29 Nm (21 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
   • Remove the bolts and the connecting rod cap.
   • Discard the connecting rod cap bolts.
     Fig 12: Measuring Connecting Rod Large End Bore In Two Directions

     Courtesy of FORD MOTOR CO.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
   Fig 13: Measuring Crankshaft Connecting Rod Bearing Journal Diameters In At Least Two Directions

   Courtesy of FORD MOTOR CO.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    Fig 14: Connecting Rod Bearings Selection Chart

    Courtesy of FORD MOTOR CO.
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
NOTE: The center bulkhead is the thrust bearing.
Fig 15: Locating Main Bearings
Courtesy of FORD MOTOR CO.
11. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Fig 16: Locating Main Bearings
Courtesy of FORD MOTOR CO.
12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.
    Fig 17: Locating Crankshaft

    Courtesy of FORD MOTOR CO.
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
    Fig 18: Locating Main Bearing Beam Side Fit Surfaces

    Courtesy of FORD MOTOR CO.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    Fig 19: Locating Main Bearing Beam

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.
17. Install and tighten the 10 new main bearing beam bolts.
    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
      Fig 20: Identifying Main Bearing Beam Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
18. 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 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
      Fig 21: Measuring Crankshaft End Play

      Courtesy of FORD MOTOR CO.
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 arrow on top is facing toward the front of the engine.
19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
    • When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
    • The position of the upper and lower compression ring gaps are not controlled for installation.
      Fig 22: Identifying Piston Ring Compressor And Connecting Rod Installer

      Courtesy of FORD MOTOR CO.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
20. Install the connecting rod caps and the new bolts.
    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 23: Identifying Connecting Rod Cap Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
21. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).
    Fig 24: Locating Crankshaft TDC Timing Peg

    Courtesy of FORD MOTOR CO.
NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
NOTE: The original adjustment shims must be installed in their original position.
NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
22. Install the adjustment shims in their original position on the seat faces of the balancer unit.
23. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
    Fig 25: Locating Balancer Unit Shaft Marks At TDC Position

    Courtesy of FORD MOTOR CO.
24. Install the balancer unit bolts.
    • Tighten in the sequence shown in 2 stages.
      • Stage 1: Tighten to 25 Nm (18 lb-ft).
      • Stage 2: Tighten to 50 Nm (37 lb-ft).
        Fig 26: Identifying Balancer Unit Bolts Tightening Sequence

        Courtesy of FORD MOTOR CO.
25. Remove the Crankshaft TDC Timing Peg.
    Fig 27: Locating Crankshaft TDC Timing Peg

    Courtesy of FORD MOTOR CO.
26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
27. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
    • Remove the Crankshaft TDC Timing Peg.
      Fig 28: Locating Crankshaft TDC Timing Peg

      Courtesy of FORD MOTOR CO.
NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crank weight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown.
28. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
    • Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
    • Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
    • If the backlash exceeds the specified range, carry out the balance shaft backlash procedure. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
      Fig 29: Measuring Gear Backlash

      Courtesy of FORD MOTOR CO.
NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
29. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
Fig 30: Locating Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
30. Install the Crankshaft TDC Timing Peg.
31. Install the block-off plate and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 31: Locating Block-Off Plate Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.
32. Install the oil pump assembly. Tighten the bolts in the sequence shown in the following 2 stages:
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 20 Nm (177 lb-in).
      Fig 32: Identifying Oil Pump Assembly Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
33. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 Nm (89 lb-in).
      Fig 33: Locating Bolts, Oil Pump Pickup Tube And Gasket

      Courtesy of FORD MOTOR CO.
34. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.
    Fig 34: Positioning Crankshaft Rear Oil Seal With Retainer Plate Onto Crankshaft

    Courtesy of FORD MOTOR CO.
35. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
      Fig 35: Identifying Crankshaft Rear Oil Seal Retainer Plate Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool and metal surface cleaner to remove traces of sealant.
36. Clean and inspect all mating surfaces.
NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
37. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
38. Install the oil pan and install the 2 oil pan bolts finger-tight.
    Fig 36: Locating Oil Pan Silicone Gasket And Sealant Bead

    Courtesy of FORD MOTOR CO.
39. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.
    Fig 37: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block

    Courtesy of FORD MOTOR CO.
40. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 38: Identifying Oil Pan Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
41. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 39: Locating Cylinder Head Alignment Dowels

    Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
42. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
43. Apply silicone gasket and sealant to the locations shown.
    Fig 40: Locating Silicone Gasket And Sealant Applying Locations

    Courtesy of FORD MOTOR CO.
44. Install a new head gasket.
    Fig 41: Locating Head Gasket

    Courtesy of FORD MOTOR CO.
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
45. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in the following 5 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 15 Nm (133 lb-in).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
      Fig 42: Identifying Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
46. Install the valve tappets.
NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
47. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
    • Stage 1: Tighten 1 turn at a time until tight.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (142 lb-in).
      Fig 43: Identifying Camshafts Bearing Cap Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
48. Install the Variable Camshaft Timing (VCT) system oil filter and plug in the intake camshaft thrust cap.
    • Tighten to 17 Nm (150 lb-in).
      Fig 44: Locating Plug And VCT System Oil Filter

      Courtesy of FORD MOTOR CO.
49. Install the VCT solenoid and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 45: Locating Bolt And Variable Camshaft Timing Solenoid

      Courtesy of FORD MOTOR CO.
NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
50. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
    • The crankshaft sprocket flange must be facing away from the engine block.
      Fig 46: Locating Crankshaft Sprocket

      Courtesy of FORD MOTOR CO.
51. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 47: Locating Oil Pump Chain, Sprocket And Bolt

      Courtesy of FORD MOTOR CO.
52. Install the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 48: Locating Shoulder Bolt

      Courtesy of FORD MOTOR CO.
53. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 49: Locating Oil Pump Drive Chain Tensioner, Tensioner Spring And Shoulder Bolt

      Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
Fig 50: Identifying Camshaft Alignment Plate In Slots On Rear Of Both Camshafts
Courtesy of FORD MOTOR CO.
54. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
55. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    Fig 51: Locating Camshaft Sprockets And Bolts

    Courtesy of FORD MOTOR CO.
56. Install the LH timing chain guide and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 52: Locating Timing Chain Guide Bolts

      Courtesy of FORD MOTOR CO.
57. Install the timing chain.
    Fig 53: Locating Timing Chain

    Courtesy of FORD MOTOR CO.
58. Install the RH timing chain guide.
    Fig 54: Locating RH Timing Chain Guide

    Courtesy of FORD MOTOR CO.
    NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Fig 55: Locating Timing Chain Tensioner Plunger
Courtesy of FORD MOTOR CO.
59. Using the edge of a vise, compress the timing chain tensioner plunger.
60. Using a small pick, push back and hold the ratchet mechanism.
    Fig 56: Pushing Back And Hold Ratchet Mechanism

    Courtesy of FORD MOTOR CO.
61. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 57: Pushing Ratchet Arm Back Into Tensioner Housing

    Courtesy of FORD MOTOR CO.
62. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 58: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet Assembly And Plunger In During Installation

    Courtesy of FORD MOTOR CO.
63. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
      Fig 59: Locating Timing Chain Tensioner Bolts And Paper Clip

      Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
64. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • Tighten to 72 Nm (53 lb-ft).
      Fig 60: Locating Camshaft Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
65. Clean and inspect the mounting surfaces of the engine and the front cover.
NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
Fig 61: Locating Front Cover Silicone Gasket And Sealant Bead
Courtesy of FORD MOTOR CO.
66. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
67. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
    • Tighten the 8-mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
      Fig 62: Identifying Engine Front Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer.
NOTE: Lubricate the oil seal with clean engine oil.
Fig 63: Installing Crankshaft Front Oil Seal
Courtesy of FORD MOTOR CO.
68. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
Fig 64: Positioning Crankshaft Pulley Hole At 6 O'Clock Position
Courtesy of FORD MOTOR CO.
69. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
NOTE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
Fig 65: Locating Crankshaft Pulley Through Bolt (6 mm x 18 mm)
Courtesy of FORD MOTOR CO.
70. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
71. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (one-fourth turn).
      Fig 66: Locating Crankshaft Pulley Bolt

      Courtesy of FORD MOTOR CO.
72. Remove the 6 mm x 18 mm bolt.
    Fig 67: Locating Crankshaft Pulley Through Bolt (6 mm x 18 mm)

    Courtesy of FORD MOTOR CO.
73. Remove the Crankshaft TDC Timing Peg.
    Fig 68: Locating Crankshaft TDC Timing Peg

    Courtesy of FORD MOTOR CO.
74. Remove the Camshaft Alignment Plate.
    Fig 69: Identifying Camshaft Alignment Plate In Slots On Rear Of Both Camshafts

    Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
75. Turn the crankshaft clockwise one and three-fourth turns.
76. Install the Crankshaft TDC Timing Peg.
    Fig 70: Locating Crankshaft TDC Timing Peg

    Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
Fig 71: Locating Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
77. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
78. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected.
      Fig 72: Locating Crankshaft Pulley Through Bolt (6 mm x 18 mm)

      Courtesy of FORD MOTOR CO.
79. Install the Camshaft Alignment Plate to check the position of the camshafts.
    • If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
      Fig 73: Identifying Camshaft Alignment Plate In Slots On Rear Of Both Camshafts

      Courtesy of FORD MOTOR CO.
80. Remove the Camshaft Alignment Plate.
    Fig 74: Identifying Camshaft Alignment Plate In Slots On Rear Of Both Camshafts

    Courtesy of FORD MOTOR CO.
81. Install the Crankshaft Position (CKP) sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
      Fig 75: Locating Bolts And CKP Sensor

      Courtesy of FORD MOTOR CO.
82. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
    • Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
      Fig 76: Identifying Crankshaft Sensor Aligner

      Courtesy of FORD MOTOR CO.
83. Remove the 6 mm x 18 mm bolt.
    Fig 77: Locating Crankshaft Pulley Through Bolt (6 mm x 18 mm)

    Courtesy of FORD MOTOR CO.
84. Remove the Crankshaft TDC Timing Peg.
    Fig 78: Locating Crankshaft TDC Timing Peg

    Courtesy of FORD MOTOR CO.
85. Install the engine plug bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 79: Locating Engine Plug Bolt

      Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
86. Clean the valve cover gasket surface with metal surface prep.
87. Apply silicone gasket and sealant to the locations shown.
    Fig 80: Locating Silicone Gasket And Sealant Applying Locations

    Courtesy of FORD MOTOR CO.
NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
88. Install the valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
      Fig 81: Identifying Valve Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.
Fig 82: Locating Oil Level Indicator
Courtesy of FORD MOTOR CO.
89. Install the oil level indicator.
NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
90. Install the Cylinder Head Temperature (CHT) sensor and the spark plugs.
    • Tighten the CHT sensor to 12 Nm (106 lb-in).
    • Tighten the spark plugs to 12 Nm (106 lb-in).
      Fig 83: Locating Spark Plugs And CHT Sensor

      Courtesy of FORD MOTOR CO.
NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
91. Install the 4 coil-on-plugs and the 4 bolts. Install the crankshaft vent tube.
    • Tighten to 8 Nm (71 lb-in).
      Fig 84: Locating Coil-On-Plugs Stud Bolts

      Courtesy of FORD MOTOR CO.
92. Install the engine cover studs.
    Fig 85: Locating Engine Cover Studs

    Courtesy of FORD MOTOR CO.
93. Install the crankshaft vent tube.
    Fig 86: Locating Crankshaft Vent Tube

    Courtesy of FORD MOTOR CO.
94. If equipped, install the block heater.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 87: Locating Block Heater

      Courtesy of FORD MOTOR CO.
NOTE: Clean the gasket mating surfaces with metal surface cleaner.
NOTE: Spin-on oil filter adapter shown, element oil filter adapter similar.
95. Install the oil filter adapter with a new gasket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 88: Locating Oil Filter Adapter Bolts

      Courtesy of FORD MOTOR CO.
96. Install the crankcase vent oil separator and the 8 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 89: Locating Bolts And Crankcase Vent Oil Separator

      Courtesy of FORD MOTOR CO.
NOTE: The Knock Sensor (KS) must not touch 100. Install the coolant hose, the crankcase vent oil separator.
97. Install the KS and the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 90: Locating Bolt And KS

      Courtesy of FORD MOTOR CO.
98. Install the vacuum pump assembly, the nut and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 91: Locating Bolts, Nut And Vacuum Pump Assembly

      Courtesy of FORD MOTOR CO.
99. Install the coolant hose.
    Fig 92: Locating Coolant Hose

    Courtesy of FORD MOTOR CO.
100. Install the coolant hose.
     Fig 93: Locating Coolant Hose

     Courtesy of FORD MOTOR CO.
NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
101. Install the thermostat housing.
     • Tighten to 10 Nm (89 lb-in).
       Fig 94: Locating Bolts And Thermostat Housing

       Courtesy of FORD MOTOR CO.
102. Connect the EGR coolant hose and the heater hose.
     Fig 95: Locating EGR Coolant Hose And Heater Hose

     Courtesy of FORD MOTOR CO.
103. Install the coolant hose.
     Fig 96: Locating Coolant Hose

     Courtesy of FORD MOTOR CO.
NOTE: Make sure the coolant pump is correctly seated to the engine block before installing and tightening the fasteners, or damage to the coolant pump may occur.
NOTE: Clean the coolant pump mating surface with metal surface cleaner.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
104. Install the new O-ring, coolant pump and the 3 bolts.
     • Tighten to 10 Nm (89 lb-in).
       Fig 97: Locating Bolts And Coolant Pump

       Courtesy of FORD MOTOR CO.
105. Install the coolant pump pulley and bolts.
     • Tighten to 20 Nm (177 lb-in).
       Fig 98: Locating Bolts And Coolant Pump Pulley

       Courtesy of FORD MOTOR CO.
106. Position the engine control wiring harness on the engine.
107. Attach the wiring harness retainer to the valve cover stud.
     • Connect the EGR valve electrical connector.
       Fig 99: Locating EGR Valve Electrical Connector And Wiring Harness Retainer

       Courtesy of FORD MOTOR CO.
108. Connect the CHT sensor and install the rubber boot.
     Fig 100: Locating Rubber Boot And Cylinder Head Temperature Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
109. Connect the 4 coil-on-plug electrical connectors.
     Fig 101: Locating Coil-On-Plug Electrical Connectors

     Courtesy of FORD MOTOR CO.
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.
110. 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 102: Locating Fuel Injector O-Rings

       Courtesy of FORD MOTOR CO.
111. Install the fuel rail with the fuel injectors and stud bolts.
     • Tighten to 23 Nm (17 lb-ft).
       Fig 103: Locating Stud Bolts

       Courtesy of FORD MOTOR CO.
112. Install the radio capacitor and the nut.
     • Tighten to 10 Nm (89 lb-in).
       Fig 104: Locating Nut And Radio Capacitor

       Courtesy of FORD MOTOR CO.
113. Install the fuel rail insulator.
     Fig 105: Locating Fuel Rail Insulator

     Courtesy of FORD MOTOR CO.
114. Position the high voltage wiring harness and attach the 2 wiring harness retainers to the ignition coil stud bolts.
     Fig 106: Locating Wiring Harness Retainers

     Courtesy of FORD MOTOR CO.
115. Connect the VCT electrical connector and attach the wiring harness retainer to the valve cover stud bolt.
     Fig 107: Locating VCT Oil Control Solenoid Electrical Connector And Wiring Harness Retainer

     Courtesy of FORD MOTOR CO.
116. Attach the 2 wiring harness retainers to the fuel rail and the from the valve cover.
     Fig 108: Locating Wiring Harness Retainers

     Courtesy of FORD MOTOR CO.
117. Connect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
     Fig 109: Locating Fuel Injector Electrical Connectors, Radio Capacitor Electrical Connector And CMP Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
118. Install the EGR tube.
     • Tighten to 55 Nm (41 lb-ft).
       Fig 110: Locating EGR Tube

       Courtesy of FORD MOTOR CO.
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.
Fig 111: Locating PCV Hose Connector
Courtesy of FORD MOTOR CO.
119. Position the intake manifold and connect the PCV hose.
NOTE: Inspect and install new intake manifold gaskets, if necessary.
NOTE: The cylinder head side of the intake manifold is showing bolt location.
120. Install the intake manifold gasket, intake manifold and 7 bolts.
     • Tighten to 18 Nm (159 lb-in).
       Fig 112: Locating Intake Manifold Bolts

       Courtesy of FORD MOTOR CO.
121. Attach the 4 wire harness pin-type retainers to the intake manifold.
     Fig 113: Locating Wire Harness Pin-Type Retainers

     Courtesy of FORD MOTOR CO.
122. Attach the pin-type retainer to the intake manifold and connect the KS electrical connector.
     Fig 114: Locating Knock Sensor Electrical Connector And Electrical Connector Pin-Type Retainer

     Courtesy of FORD MOTOR CO.
123. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
     Fig 115: Locating Manifold Absolute Pressure Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
124. Connect the Engine Oil Pressure (EOP) switch electrical connector.
     Fig 116: Locating Engine Oil Pressure Switch Electrical Connector

     Courtesy of FORD MOTOR CO.
125. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
     Fig 117: Locating Evaporative Emission Canister Purge Valve Electrical Connector

     Courtesy of FORD MOTOR CO.
126. Connect the electronic throttle control electrical connector.
     Fig 118: Locating Electronic Throttle Control Electrical Connector

     Courtesy of FORD MOTOR CO.
127. Install the accessory drive belt tensioner.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 119: Locating Bolts And Accessory Drive Belt Tensioner

       Courtesy of FORD MOTOR CO.
128. Install 7 new exhaust manifold studs in the cylinder head.
     • Tighten to 17 Nm (150 lb-in).
       Fig 120: Locating Exhaust Manifold Studs

       Courtesy of FORD MOTOR CO.
129. Install the new exhaust manifold gasket on the engine.
NOTE: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
NOTE: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
130. Position the catalytic converter and tighten the 7 new nuts in the sequence shown in 2 stages:
     • Stage 1: Tighten to 48 Nm (35 lb-ft).
     • Stage 2: Tighten to 48 Nm (35 lb-ft).
       Fig 121: Locating Catalytic Converter Manifold Nuts

       Courtesy of FORD MOTOR CO.
131. Attach the 2 wiring harness pin-type retainers.
     Fig 122: Locating Engine Wiring Harness Pin-Type Retainers

     Courtesy of FORD MOTOR CO.
132. Install the engine wiring harness connector bracket.
     • Tighten to 15 Nm (133 lb-in).
       Fig 123: Locating Bolt And Engine Wiring Harness Connector Bracket

       Courtesy of FORD MOTOR CO.
133. Connect the Crankshaft Position (CKP) sensor electrical connector.
     Fig 124: Locating Crankshaft Position Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
134. Connect the Catalyst Monitor Sensor (CMS) electrical connector.
     Fig 125: Locating Catalyst Monitor Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
135. Connect the Heated Oxygen Sensor (HO2S) connector. Attach the connector to the engine wiring harness connector bracket.
     Fig 126: Locating Locking Tab And Heated Oxygen Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
136. Using the Heavy Duty Floor Crane and the Spreader Bar, remove the engine from the engine stand.
NOTE: Special bolts are used for installation. Do not use standard bolts.
137. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following 3 stages:
     • Stage 1: Tighten to 50 Nm (37 lb-ft).
     • Stage 2: Tighten to 80 Nm (59 lb-ft).
     • Stage 3: Tighten to 112 Nm (83 lb-ft).
       Fig 127: Identifying Flywheel Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.