LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 1999 >> Contour SVT >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Engine - 3.0L (4V)) >> Disassembly And Assembly Of Subassemblies >> Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Disassembly And Assembly Of Subassemblies: Assembly

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
ENGINE ASSEMBLY SPECIAL TOOL CHART

G03898521
 Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A)
G03901093
 Installation, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
G03920628
 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
G03898522
 Installer, Crankshaft Rear Main Bolts 303-384 (T91P-6701-A)
G03889585
 Strap Wrench 303-D055 (D85L-6000-A)
G03898369
 Lifting Brackets, Engine 303-050
ENGINE ASSEMBLY MATERIAL SPECIFICATION

Item Specification
Silicone Gasket and Sealant TA-30 or equivalent WSE-M4G323-A4
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7B, in Canada CVC-7-C) or equivalent WSS-M97B51-A1
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
Fig 1: Exploded View Of Engine Assembly (1 Of 3)
G03996080Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Engine Assembly (2 Of 3)
G03996081Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Engine Assembly (3 Of 3)
G03996082Courtesy of FORD MOTOR CO.
  1. Position the oil pump and install the 4 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    Fig 4: Tightening Oil Pump Bolts
    G03898365Courtesy of FORD MOTOR CO.
  2. Install the oil separator cover, a new gasket and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 5: Installing Oil Separator Cover, New Gasket And Bolts
    G03996069Courtesy of FORD MOTOR CO.
  3. Position the knock sensor (KS) and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    • Attach the wiring retainer to the oil separator cover.
    Fig 6: Tightening Knock Sensor Bolt
    G03996068Courtesy of FORD MOTOR CO.
    4. NOTE: Lubricate the O-ring seal with clean engine coolant.
    Fig 7: Installing Coolant Inlet Tube, New O-Ring Seal And Bolts
    G03996067Courtesy of FORD MOTOR CO.
  4. Install the coolant inlet tube, a new O-ring seal and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    5. NOTE: Lubricate the O-ring seal with clean engine coolant.
    Fig 8: Installing Coolant Bypass Tube, New O-Ring Seal And Bolts
    G03996066Courtesy of FORD MOTOR CO.
  5. Install the coolant bypass tube, a new O-ring seal and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    6. CAUTION: The cylinder head gasket surfaces are ground to a precision finish. Do not rest cylinder heads on gasket surfaces. Do not use any abrasive materials during cleaning of the surfaces. Hairline scratches, small burrs or dirt can provide a leak path for a cylinder head gasket. If gasket material remains on the sealing surface, use only a plastic-tipped scraper to remove the material. Do not attempt to reuse the head gaskets.
    CAUTION: Cylinder head bolts are torque-to-yield and cannot be reused.
    NOTE: The LH and RH cylinder head gaskets are not interchangeable.
    Fig 9: Identifying Cylinder Bolt Tightening Sequence
    G03995845Courtesy of FORD MOTOR CO.
  6. Position the new gaskets and the RH and LH cylinder heads. Install new bolts and tighten in the sequence shown in 6 stages.
    • Stage 1: Tighten to 30 Nm (22 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Back out a minimum of one full turn (360 degrees).
    • Stage 4: Tighten to 30 Nm (22 lb-ft).
    • Stage 5: Tighten an additional 90 degrees.
    • Stage 6: Tighten an additional 90 degrees.
    7. NOTE: Be sure camshaft bearing caps are installed in their original positions.
    Fig 10: Positioning Camshafts Into Cylinder Head
    G03996064Courtesy of FORD MOTOR CO.
  7. Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head.
    8. CAUTION: 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.
    Fig 11: Installing Bearing Caps And Bolts
    G03996063Courtesy of FORD MOTOR CO.
  8. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil, install the bearing caps and loosely install the bolts.
  9. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil, install the thrust caps and loosely install the bolts.
    Fig 12: Installing Thrust Caps And Bolts
    G03996061Courtesy of FORD MOTOR CO.
  10. Tighten the bolts in the sequence shown.
    Fig 13: Tightening Bolts In Sequence
    G03996092Courtesy of FORD MOTOR CO.
    11. NOTE: If new camshafts were installed, refer to VALVE CLEARANCE ADJUSTMENT  in this article .
  11. Lubricate the tappet shims and camshaft lobes with clean engine oil.
  12. Rotate the camshafts to make sure they are not binding. If binding occurs, check to make sure that all bearing caps are in their original positions. Loosen all bearing cap bolts in reverse order and retighten.
  13. Install the LH variable camshaft timing (VCT) actuator and install a new bolt hand-tight. Use a wrench on the flats of the camshaft to hold it in position and tighten the bolt in 2 stages.
    • Stage 1: Tighten the VCT actuator bolt to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 14: Tightening VCT Actuator Bolt
    G03995802Courtesy of FORD MOTOR CO.
  14. Install the LH exhaust camshaft sprocket and install a new bolt hand-tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages.
    • Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 15: Installing LH Exhaust Camshaft Sprocket And Bolt
    G03995803Courtesy of FORD MOTOR CO.
  15. Install the RH variable camshaft timing (VCT) actuator and install a new bolt hand-tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages.
    • Stage 1: Tighten the VCT actuator bolt to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 16: Installing RH Variable Camshaft Timing (VCT) Actuator And Bolt
    G03995800Courtesy of FORD MOTOR CO.
  16. Install the RH exhaust camshaft sprocket and install a new bolt hand-tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in 2 stages.
    • Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 17: Installing RH Exhaust Camshaft Sprocket And Bolt
    G03995801Courtesy of FORD MOTOR CO.
  17. With the 2 keyways facing forward, install the crankshaft sprockets.
    Fig 18: Installing Crankshaft Sprockets
    G03995804Courtesy of FORD MOTOR CO.
  18. If the 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 exhaust camshaft timing mark.
    2. Starting with the exhaust camshaft timing mark, count 16 links and mark the link as the intake camshaft sprocket timing mark.
    3. Starting with the intake camshaft timing mark, count 25 links and mark the link as the crankshaft sprocket timing mark.
    Fig 19: Identifying Crankshaft Sprocket Timing Marks
    G03996098Courtesy of FORD MOTOR CO.
  19. Verify that the crankshaft key way is in the 11 o'clock position.
    Fig 20: Locating Crankshaft Keyway At 11 O'Clock Position
    G03995811Courtesy of FORD MOTOR CO.
    20. CAUTION: The crankshaft keyway must remain in the 11 o'clock position until the cams are located in the NEUTRAL position, or damage to the valves can occur.
    Fig 21: Rotating LH And RH Intake And Exhaust Camshafts
    G03995812Courtesy of FORD MOTOR CO.
  20. Rotate the LH and RH intake and exhaust camshafts to locate them in their NEUTRAL positions.
    21. NOTE: The gold-colored bolt (No. 2 location) must be installed in its original location.
    Fig 22: Installing LH VCT Solenoid Housing Assembly And Bolts
    G03995813Courtesy of FORD MOTOR CO.
  21. Install the LH VCT solenoid housing assembly and hand-tighten the bolts.
    • Tighten in the sequence shown to 25 Nm (18 lb-ft).
  22. Install the LH timing chain, aligning the copper (or marked) link with the marks on the camshaft and crankshaft sprockets.
    Fig 23: Installing LH Timing Chain, Aligning Copper (Or Marked) Link With Marks
    G03995814Courtesy of FORD MOTOR CO.
  23. Install the LH timing chain tensioner arm.
    Fig 24: Installing LH Timing Chain Tensioner Arm
    G03995797Courtesy of FORD MOTOR CO.
    24. NOTE: Be sure to position the tensioner so that the tensioner piston is fully engaged in the tensioner arm.
    Fig 25: Installing LH Timing Chain Tensioner And Bolts
    G03995816Courtesy of FORD MOTOR CO.
  24. Install the LH timing chain tensioner and bolts.
  25. Remove the wire or paper clip from the tensioner.
    Fig 26: Identifying Wire Or Paper Clip At Tensioner
    G03995817Courtesy of FORD MOTOR CO.
  26. Rotate the crankshaft clockwise and position the keyway at the 3 o'clock position for RH timing chain installation.
    Fig 27: Positioning Keyway At 3 O'Clock Position For RH Timing Chain Installation
    G03995819Courtesy of FORD MOTOR CO.
  27. Verify that the copper (or marked) links on the LH timing chain are in alignment with the timing marks on the camshaft and crankshaft sprockets.
    28. Fig 28: Verifying Copper (Or Marked) Links On LH Timing Chain
    G03996107Courtesy of FORD MOTOR CO.
  28. Install the RH VCT solenoid housing assembly and hand-tighten bolts.
    • Tighten in the sequence shown to 25 Nm (18 lb-ft).
    Fig 29: Installing RH VCT Solenoid Housing Assembly And Bolts
    G03995820Courtesy of FORD MOTOR CO.
  29. Install the RH timing chain, aligning the copper or (marked) links with the marks on the camshaft and crankshaft sprockets.
    Fig 30: Aligning Copper Or (Marked) Links With Marks On Camshaft And Crankshaft Sprockets
    G03995821Courtesy of FORD MOTOR CO.
  30. Install the RH timing chain tensioner arm.
    Fig 31: Installing RH Timing Chain Tensioner Arm
    G03995791Courtesy of FORD MOTOR CO.
  31. Install the RH timing chain tensioner and bolts.
    Fig 32: Installing RH Timing Chain Tensioner And Bolts
    G03995823Courtesy of FORD MOTOR CO.
  32. Remove the wire or paper clip from the RH timing chain tensioner.
    Fig 33: Installing RH Timing Chain Tensioner And Bolts
    G03995824Courtesy of FORD MOTOR CO.
  33. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the 11 o'clock position.
    Fig 34: Positioning Crankshaft Keyway To 11 O'Clock Position
    G03995794Courtesy of FORD MOTOR CO.
    34. CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.
  34. Verify that the timing component alignment is correct.
    1. There should be 14 chain links between the exhaust and intake camshaft timing marks.
    2. There should be 23 chain links between the camshaft and crankshaft timing marks.
    3. There should be 28 chain links between the camshaft and crankshaft timing marks.
    35. Fig 35: Identifying Correct Timing Component Alignment
    G03995825Courtesy of FORD MOTOR CO.
  35. Remove the crankshaft damper bolt and washer.
    Fig 36: Identifying Crankshaft Damper Bolt And Washer
    G03995785Courtesy of FORD MOTOR CO.
    36. CAUTION: This pulse wheel is used with several different engines. Install the pulse wheel with the keyway in the slot stamped "20-25-30 DAMB 30 RFF" only. This slot is also marked with an orange paint mark and aligns with the missing tooth in the trigger wheel.
    Fig 37: Installing Ignition Pulse Wheel Using Orange Marked Keyway Slot And Teeth Facing Forward
    G03995784Courtesy of FORD MOTOR CO.
    Fig 38: Installing Ignition Pulse Wheel Using Orange Marked Keyway Slot And Teeth Facing Forward
    G03996117Courtesy of FORD MOTOR CO.
  36. Install the ignition pulse wheel using the orange marked keyway slot and the teeth facing forward.
  37. Install new gaskets on the engine front cover.
    38. NOTE: Clean the sealing surfaces with silicone gasket remover and 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.
  38. 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.
  39. Install new gaskets on the engine front cover.
  40. Install the engine front cover and the 15 bolts.
    • Tighten the bolts in the sequence shown to 25 Nm (18 lb-ft).
    Fig 39: Tightening Engine Front Cover Bolts In Sequence
    G03995782Courtesy of FORD MOTOR CO.
  41. Install the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 40: Installing Crankshaft Position Sensor And Bolt
    G03996037Courtesy of FORD MOTOR CO.
  42. Install the RH and LH camshaft position (CMP) sensors and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 41: Installing RH And LH Camshaft Position Sensors And 2 Bolts
    G03996036Courtesy of FORD MOTOR CO.
  43. Install the oil pan baffle and the 5 nuts.
    • Tighten to 20 Nm (15 lb-ft) and then rotate 45 degrees.
    Fig 42: Installing Oil Pan Baffle And Nuts
    G03996035Courtesy of FORD MOTOR CO.
    44. NOTE: Lubricate the new oil pump screen and pickup tube O-ring seal with clean engine oil.
    Fig 43: Installing Oil Pump Screen And Pickup Tube
    G03996034Courtesy of FORD MOTOR CO.
  44. Position the oil pump screen and pickup tube and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    45. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep before applying gasket and sealant.
    NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.
    Fig 44: Applying Silicone Gasket And Sealant Onto The Top Of The New Oil Pan Gasket
    G03995866Courtesy of FORD MOTOR CO.
  45. Apply a 10-mm (0.4-in) dot of silicone gasket and sealant onto the top of the new oil pan gasket at the 2 locations shown.
    46. NOTE: The oil pan rear face must be installed flush to the cylinder block rear face to within +/- 0.10 mm (0.0039 in). Failure to maintain this specification will require the oil pan to be removed and installed again.
    Fig 45: Aligning Rear Face Of Oil Pan With Rear Face Of Cylinder Block
    G03996124Courtesy of FORD MOTOR CO.
  46. Install a new gasket and the oil pan.
    • Using a straightedge, align the rear face of the oil pan with the rear face of the cylinder block.
  47. Tighten the oil pan bolts in the sequence shown.
    Fig 46: Tightening Oil Pan Bolts In Sequence
    G03995868Courtesy of FORD MOTOR CO.
    48. NOTE: Clean and inspect all sealing surfaces. Inspect and install new gaskets as necessary.
    Fig 47: Tightening Lower Intake Manifold Bolts
    G03995748Courtesy of FORD MOTOR CO.
  48. Position the lower intake manifold and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
  49. Install the fuel tube bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 48: Installing Fuel Tube Bracket Bolt
    G03995780Courtesy of FORD MOTOR CO.
  50. Install new gaskets in the RH valve cover.
    51. NOTE: Clean the RH valve cover sealing surfaces with silicone gasket remover and metal surface prep before applying gasket and sealant.
    NOTE: The valve cover must be installed and the bolts tightened within 4 minutes of sealant application.
    Fig 49: Applying Bead Of Silicone Gasket And Sealant To The Cylinder Half Round Surface And To The Front Cover Gasket Intersections
    G03996128Courtesy of FORD MOTOR CO.
  51. Apply an 8-mm (0.32-in) bead of silicone gasket and sealant to the cylinder half round surface and to the front cover gasket intersection places.
  52. Position the RH valve cover and install the 12 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    Fig 50: Tightening RH Valve Cover Bolts
    G03995757Courtesy of FORD MOTOR CO.
  53. Connect the crankcase vent tube to the RH valve cover.
    Fig 51: Connecting Crankcase Vent Tube To RH Valve Cover
    G03996029Courtesy of FORD MOTOR CO.
  54. Install the upper intake manifold support bracket and the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
    Fig 52: Installing Upper Intake Manifold Support Bracket And Nuts
    G03996028Courtesy of FORD MOTOR CO.
  55. Install new gaskets in the LH valve cover.
    56. NOTE: Clean the LH valve cover sealing surfaces with silicone gasket remover and metal surface prep before applying gasket and sealant.
    NOTE: The valve cover must be installed and the bolts tightened within 4 minutes of sealant application.
    Fig 53: Applying Bead Of Silicone Gasket And Sealant To The Cylinder Half Round Surface And To The Front Cover Gasket Intersections
    G03996132Courtesy of FORD MOTOR CO.
  56. Apply an 8-mm (0.32-in) bead of silicone gasket and sealant to the cylinder half round surface and to the front cover gasket intersection places.
  57. Position the LH valve cover and install the bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    Fig 54: Tightening LH Valve Cover Bolts
    G03995753Courtesy of FORD MOTOR CO.
  58. Install the engine appearance cover bracket and the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
    Fig 55: Installing Engine Appearance Cover Bracket And Nuts
    G03996026Courtesy of FORD MOTOR CO.
    59. NOTE: The cylinder head temperature (CHT) sensor can not be reused, a new CHT must be installed
    Fig 56: Installing New CHT
    G03996025Courtesy of FORD MOTOR CO.
  59. Install a new CHT.
    • Tighten to 15 Nm (11 lb-ft).
    60. NOTE: RH shown, LH similar.
    NOTE: Apply a light film of silicone brake caliper grease and dielectric compound to the inside of the coil boots before installation.
    Fig 57: Installing Ignition Coils Bolts
    G03996024Courtesy of FORD MOTOR CO.
  60. Install the 6 ignition coils the 6 bolts.
    • Tighten to 7 Nm (62 lb-in).
  61. Install the oil pressure switch and oil temperature sensor.
    • Tighten to 14 Nm (10 lb-ft).
    Fig 58: Installing Oil Pressure Switch And Oil Temperature Sensor
    G03996023Courtesy of FORD MOTOR CO.
  62. Position the generator and install the 3 bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 59: Installing Generator Bolts
    G03996022Courtesy of FORD MOTOR CO.
  63. Install the 6 new RH exhaust manifold studs.
    • Tighten to 9 Nm (80 lb-in).
  64. Position a new gasket and the RH exhaust manifold. Install the 6 new nuts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
    Fig 60: Installing RH Exhaust Manifold
    G03995884Courtesy of FORD MOTOR CO.
  65. Position the RH exhaust manifold heat shield and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 61: Installing RH Exhaust Manifold Heat Shield And Bolts
    G03996019Courtesy of FORD MOTOR CO.
  66. Install the RH engine mount bracket and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 62: Installing RH Engine Mount Bracket And Bolts
    G03996021Courtesy of FORD MOTOR CO.
    67. NOTE: Install a new O-ring seal on the banjo bolt and lubricate the seal with clean engine oil.
    Fig 63: Tightening Banjo Bolt
    G03996018Courtesy of FORD MOTOR CO.
  67. Position the oil filter adapter and loosely install the 2 bolts, the stud bolt and the banjo bolt. Tighten the bolts in 5 stages.
    • Stage 1: Tighten the banjo bolt to 30 Nm (22 lb-ft).
    • Stage 2: Tighten the 2 M10 bolts to 26 Nm (19 lb-ft).
    • Stage 3: Tighten the stud bolt to 25 Nm (18 lb-ft).
    • Stage 4: Tighten the banjo bolt to 155 Nm (114 lb-ft).
    • Stage 5: Tighten the 2 M10 bolts to 40 Nm (30 lb-ft) and the rotate 90 degrees.
  68. Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.
    69. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
    Fig 64: Installing Oil Cooler And Bolt
    G03996017Courtesy of FORD MOTOR CO.
  69. If equipped, position the oil cooler and loosely install the bolt. Rotate the oil cooler clockwise until the locating pin hits the stop.
    • Tighten to 57 Nm (42 lb-ft).
  70. Install the accessory drive belt tensioner and the bolt.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 65: Installing Accessory Drive Belt Tensioner And Bolt
    G03996016Courtesy of FORD MOTOR CO.
  71. Using the special tool, install the crankshaft front oil seal.
    Fig 66: Installing Crankshaft Front Oil Seal
    G03995771Courtesy of FORD MOTOR CO.
    72. NOTE: Install the crankshaft damper no more than 4 minutes after applying the sealer.
    Fig 67: Identifying Silicone Sealant Application Area At End Of Keyway Slot
    G03995765Courtesy of FORD MOTOR CO.
  72. Apply a dot of silicone gasket and sealant to the crankshaft damper keyway slot.
  73. Using the special tool, install the crankshaft damper.
    Fig 68: Installing Crankshaft Damper
    G03995766Courtesy of FORD MOTOR CO.
  74. Using the special tool, install the washer and a new bolt. Tighten the bolt in 4 stages:
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Back out a minimum of one full turn (360 degrees).
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 69: Installing Washer And New Bolt
    G03995763Courtesy of FORD MOTOR CO.
  75. Position the A/C compressor bracket and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 70: Installing A/C Compressor Bracket And Install Bolts
    G03996012Courtesy of FORD MOTOR CO.
    76. NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil.
    Fig 71: Installing Oil Level Indicator Tube And Stud Bolt
    G03996011Courtesy of FORD MOTOR CO.
  76. Install the oil level indicator tube and the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
  77. Install the 6 new LH exhaust manifold studs.
    • Tighten to 9 Nm (80 lb-in).
  78. Position a new gasket and the LH exhaust manifold. Install the 6 new nuts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
    Fig 72: Installing LH Exhaust Manifold
    G03929084Courtesy of FORD MOTOR CO.
  79. Position the LH exhaust manifold heat shield and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 73: Installing LH Exhaust Manifold Heat Shield And Bolts
    G03996009Courtesy of FORD MOTOR CO.
  80. Position the main engine wiring harness and install the 4 wiring conduit nuts.
    • Tighten to 6 Nm (53 lb-in).
    Fig 74: Identifying Main Engine Wiring Harness Nuts
    G03996008Courtesy of FORD MOTOR CO.
  81. Position the LH HO2S bracket and install the nut.
    • Attach the wiring retainer to the LH engine mount bracket.
    • Tighten to 6 Nm (53 lb-in).
    Fig 75: Installing LH HO2S Bracket And Nut
    G03996007Courtesy of FORD MOTOR CO.
  82. Position the radio ignition interference capacitors and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 76: Identifying Radio Ignition Interference Capacitors And Bolts
    G03996005Courtesy of FORD MOTOR CO.
  83. Attach the 2 wiring harness retainers to the RH valve cover stud bolts.
    Fig 77: Attaching Wiring Harness Retainers To RH Valve Cover Stud Bolts
    G03996004Courtesy of FORD MOTOR CO.
  84. Attach the wiring harness retainers to the RH upper intake manifold support bracket.
    Fig 78: Locating Wiring Harness Retainers At Upper Intake Manifold Support Bracket
    G03996003Courtesy of FORD MOTOR CO.
  85. Connect the generator electrical connector and attach the 2 wiring harness retainers.
    Fig 79: Connecting Generator Electrical Connector
    G03996002Courtesy of FORD MOTOR CO.
  86. Attach the 3 wiring harness retainers to the LH valve cover stud bolts.
    Fig 80: Attaching Wiring Harness Retainers To LH Valve Cover Stud Bolts
    G03996001Courtesy of FORD MOTOR CO.
  87. Connect the oil pressure switch and oil temperature sensor electrical connectors.
    • Attach the 3 wiring harness retainers.
    Fig 81: Attaching Wiring Harness Retainers
    G03996000Courtesy of FORD MOTOR CO.
  88. Connect the CKP sensor electrical connector.
    Fig 82: Connecting CKP Sensor Electrical Connector
    G03995999Courtesy of FORD MOTOR CO.
    89. NOTE: LH is shown, RH is similar.
    Fig 83: Connecting LH And RH CMP Sensor Electrical Connectors
    G03995998Courtesy of FORD MOTOR CO.
  89. Connect the LH and RH CMP sensor electrical connectors.
  90. Connect the CHT sensor electrical connector.
    Fig 84: Locating Cylinder Head Temperature Sensor Electrical Connector
    G03995997Courtesy of FORD MOTOR CO.
  91. Connect the 6 ignition coil electrical connectors.
    Fig 85: Connecting Ignition Coil Electrical Connectors
    G03995996Courtesy of FORD MOTOR CO.
  92. Connect the fuel charging wiring harness connector.
    Fig 86: Locating Fuel Charging Wiring Harness Connector
    G03995995Courtesy of FORD MOTOR CO.
    93. NOTE: Inspect and install new gaskets as necessary.
    Fig 87: Installing Upper Intake Manifold And Bolts
    G03995994Courtesy of FORD MOTOR CO.
  93. Position the upper intake manifold and loosely install the 6 bolts.
  94. Tighten the 6 upper intake manifold bolts in the sequence shown to 10 Nm (89 lb-in).
    • Tighten the remaining 2 fuel pressure sensor shield bolts to 6 Nm (53 lb-in).
    Fig 88: Tightening Upper Intake Manifold Bolts
    G03995741Courtesy of FORD MOTOR CO.
  95. Position the LH engine appearance cover bracket and install the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
    Fig 89: Installing LH Engine Appearance Cover Bracket And Nuts
    G03995993Courtesy of FORD MOTOR CO.
  96. Install the RH upper intake manifold support bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 90: Installing RH Upper Intake Manifold Support Bracket Bolt
    G03995992Courtesy of FORD MOTOR CO.
  97. Connect the 2 intake manifold tuning (IMT) valve electrical connectors.
    Fig 91: Connecting Intake Manifold Tuning Valve Electrical Connectors
    G03995991Courtesy of FORD MOTOR CO.
  98. Connect the 2 throttle body electrical connectors.
    Fig 92: Connecting Throttle Body Electrical Connectors
    G03995990Courtesy of FORD MOTOR CO.
  99. Position the coolant pump and install the 2 stud bolts and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 93: Installing Coolant Pump And Stud Bolts
    G03995989Courtesy of FORD MOTOR CO.
  100. Install the coolant inlet hose.
    Fig 94: Installing Coolant Inlet Hose
    G03995988Courtesy of FORD MOTOR CO.
  101. Install the LH accessory drive belt idler pulley and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 95: Installing LH Accessory Drive Belt Idler Pulley And Bolt
    G03995987Courtesy of FORD MOTOR CO.
  102. Install the RH accessory drive belt idler pulley and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 96: Installing RH Accessory Drive Belt Idler Pulley And Bolt
    G03995986Courtesy of FORD MOTOR CO.
  103. Position the upper intake manifold support bracket and install the 2 bolts and the nut.
    • Tighten to 10 Nm (89 lb-in).
    • Attach the wiring harness retainer to the bracket.
    Fig 97: Installing Upper Intake Manifold Support Bracket And Bolts
    G03995985Courtesy of FORD MOTOR CO.
  104. Remove the 2 bolts, the nut and the upper intake manifold support bracket.
    Fig 98: Removing Bolts, Nut And Upper Intake Manifold Support Bracket
    G03995985Courtesy of FORD MOTOR CO.
  105. Connect the fuel vapor tube to the upper intake manifold and attach the retainer.
    Fig 99: Connecting Fuel Vapor Tube To Upper Intake Manifold
    G03995984Courtesy of FORD MOTOR CO.
  106. Connect the main engine vacuum harness to the fuel pressure sensor.
    Fig 100: Connecting Main Engine Vacuum Harness To Fuel Pressure Sensor
    G03995983Courtesy of FORD MOTOR CO.
  107. Install the special tool onto the engine as shown.
    Fig 101: Installing Special Tool Onto Engine
    G03995966Courtesy of FORD MOTOR CO.
  108. Install the special tool onto the engine as shown.
    Fig 102: Installing Special Tool Onto Engine
    G03995967Courtesy of FORD MOTOR CO.
  109. Using the special tools and an engine crane, transfer the engine from the stand to the floor or a bench.
  110. Install the spacer plate.
    Fig 103: Identifying Spacer Plate
    G03995981Courtesy of FORD MOTOR CO.
  111. Attach the RH heated oxygen sensor (HO2S) wiring harness retainers to the spacer plate and the oil pan.
    Fig 104: Locating RH Heated Oxygen Sensor (HO2S) Wiring Harness Connector
    G03995980Courtesy of FORD MOTOR CO.
  112. Install the flywheel and the bolts.
    • Tighten to 80 Nm (59 lb-ft).
    Fig 105: Installing Flywheel And Bolts
    G03995979Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals