Engine Mechanical: Mechanical: Engine: Installation: Engine

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1654 Lift Eyes
Floor Crane
Mounting Stand
Oil Drain Equipment

Materials 

1. Install Special Service Tool: 303-1654 Lift Eyes, 303-1246 Engine Spreader Bar. Use the General Equipment: Floor Crane

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2. Remove the engine from the mounting stand. Use the General Equipment: Mounting Stand

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3. Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be replaced.

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4. Install the crankshaft sensor ring.

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5. Apply Motorcraft® Threadlock 262 to the threads of the new bolts.

   Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

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6. NOTE: Use an universal flywheel holder (such as a Performance Tool Flywheel Turners W80510, or equivalent).

   Install the starter ring gear and the new bolts and using an universal flywheel holder tighten the bolts in sequence shown.

   Torque: 74 lb.ft (100 Nm)

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7. Using a floor crane and install the engine assembly. Use the General Equipment: Floor Crane

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8. Remove the bolts and the LH engine lift eye. Use Special Service Tool: 303-1654 Lift Eyes.

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9. Remove Special Service Tool: 303-1246 Engine Spreader Bar.

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10. Remove Special Service Tool: 303-1654 Lift Eyes.

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11. • Connect the engine harness electrical connectors.
    • Connect the PCM electrical connector.

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12. • Install the crankcase vent tube.
    • Connect the crankcase pressure sensor electrical connector.

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13. Install the crankcase vent tube.

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14. NOTE: Do not install the RH rear quarter panel assembly at this time.

    Install the rear frame structure and powertrain. Refer to: Rear Frame Structure and Powertrain .

15. Install the oil pump belt. Refer to: Oil Pump Drive Belt .
16. Install the accessory drive belt. Refer to: Accessory Drive Belt .
17. Install the intake manifold. Refer to: Intake Manifold  .
18. Install the degas bottle. Refer to: Degas Bottle .
19. NOTE: Do not start the engine or bleed the cooling system until the engine is filled with clean engine oil.

    Install the RH and LH turbochargers. Refer to: Turbocharger RH . Refer to: Turbocharger LH .

20. Install the RH turbocharger coolant supply and return tubes. Refer to: Turbocharger Coolant Supply Tube RH . Refer to: Turbocharger Coolant Return Tube RH .
21. Install the LH turbocharger coolant supply and return tubes. Refer to: Turbocharger Coolant Supply Tube LH . Refer to: Turbocharger Coolant Return Tube LH .
22. • Position the oil pump supply and return tube.
    • NOTE: Failure to maintain alignment of the flange while tightening will result in damage to the tube flanges.

      Install the bolts and alternate tightening the bolts until seated.

    • Alternate torquing the bolts to:

      Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

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23. 1. Lubricate with clean engine oil and install the new O-ring seals.

       Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

    2. NOTE: Use commercially available loctite 545 hydraulic sealant.
       NOTE: The auxiliary oil cooler supply tubes must be installed within 1 minute of the initial sealant application.

       Apply loctite 545 hydraulic sealant to 37 degree flare of the auxiliary oil cooler supply and return tubes.

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24. 1. Install the auxiliary oil cooler supply tube and the bolt finger tight.
    2. Install the auxiliary oil cooler return tube and the bolt finger tight.
    3. Install the auxiliary oil cooler supply and return tube support bracket bolt finger tight.
    4. Install and tighten the auxiliary oil cooler supply and return tube fittings finger tight.

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25. 1. Tighten the auxiliary oil cooler supply tube.

       Torque: 97 lb.in (11 Nm)

    2. Tighten the auxiliary oil cooler return tube.

       Torque: 97 lb.in (11 Nm)

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26. Index mark the auxiliary oil cooler supply tube.

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27. NOTE: Use a AN Wrench (such as an Summit Racing® AN hose end wrench, or equivalent).
    NOTE: Only use the appropriately sized AN Wrench to hold male fitting while torquing the female fitting.
    NOTE: The turn of 1 flat is equal to 160 Nm (118 lb-ft).

    Tighten to 1 flat past original mark.

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28. NOTE: This mark is for quick reference visual mark to monitor if the nut has backed off.

    Index mark the auxiliary oil cooler supply tube.

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29. Index mark the auxiliary oil cooler return tube.

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30. NOTE: Use a AN Wrench (such as an Summit Racing® AN hose end wrench, or equivalent).
    NOTE: Only use the appropriately sized AN Wrench to hold male fitting while torquing the female fitting.
    NOTE: The turn of 1 flat is equal to 160 Nm (118 lb-ft).

    Tighten to 1 flat past original mark.

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31. NOTE: This mark is for quick reference visual mark to monitor if the nut has backed off.

    Index mark the auxiliary oil cooler return tube.

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32. Tighten the auxiliary oil cooler supply and return tube support bracket bolt.

    Torque: 55 lb.in (6.2 Nm)

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33. Remove the 2 nuts (1 shown) and the RH turbocharger heat shield.

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34. Remove the nuts and the LH turbocharger heat shield.

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35. 1. Prefill a new oil filter with clean engine oil.

       Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

    2. Lubricate the oil filter gasket with clean engine oil.

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36. • Install a new oil filter and tighten in 2 stages.
    • Stage 1: Install to initial gasket contact.
    • Stage 2: Tighten 3/4 to 1 turn.

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37. NOTE: The RH CAC outlet pipe must be installed to start the engine.

    Install the RH air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe RH .

38. NOTE: The total volume of oil required to properly refill the engine oil system can vary depending on the volume of oil drained from the system components.

    Add 10.0 quarts (9.5 liters) of clean engine oil to the oil tank as an initial fill.

    Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

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39. Start the engine and idle the vehicle, if the engine stalls before the coolant temperature of 190 degrees Fahrenheit (88 degrees Celsius) is reached, perform the following 4 steps. If OK proceed to step  43.
40. Install a plastic tube onto the bleed fitting port on the auxiliary oil cooler line and the other end of the tube into the oil drain equipment. Use the General Equipment: Oil Drain Equipment

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41. NOTE: If the vehicle does not start or must be shut down before bleeding is complete, leave the bleed fitting port open during engine shut down and repeat this step with the bleed fitting port open before starting the engine.
    • Open the bleed fitting port.
    • Start the engine and let it run, initially you will get air from the bleed fitting port.
    • Allow the oil and air to bleed from the fitting until a solid stream of oil comes from the bleed fitting port. Do not drain more than 1 quart (0.946 liter) of oil in this manner.

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42. Close the bleed fitting port.

    Torque: 97 lb.in (11 Nm)

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43. Remove the plastic tube from the bleed fitting port.

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44. • Continue idling until the coolant temperature reaches 190 degrees Fahrenheit (88 degrees Celsius).
    • Turn the engine off.
    • Wait 2 to 3 minutes.

45. NOTE: Do not exceed the specified engine oil system capacity of 13.7 quarts (13 liters).

    Check the oil level by screwing dipstick in until fully seated and add as necessary to place the level between the minimum and maximum oil level marks on the dipstick.

    Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

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46. Start the engine and check for leaks.
47. Install the RH rear quarter panel assembly. Refer to: Quarter Panel Assembly .
48. Lower the vehicle and position the hoist using the front and mid lift points and raise the vehicle. Refer to: Jacking and Lifting - Overview .
49. NOTE: Apply locktite to the bolts before installation.

    Install the engine underbody cover and the bolts.

    Material: Motorcraft® Threadlock and Sealer / TA-25-B

    Torque: 60 lb.in (6.8 Nm)

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