Engine Mechanical: Mechanical: Engine: Assembly: Engine

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

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	205-142 (T80T-4000-J) Installer, Differential Bearing Cone
Courtesy of FORD MOTOR COMPANY	205-149 (T80T-4000-R) Installer, Spindle Bearing
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-102 Installer, Crankshaft Pulley
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1251 Installer, Front Seal TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1633 Remover, Roller Rocker Follower TKIT-2014D-ROW3 TKIT-2014D-FL_ROW
Courtesy of FORD MOTOR COMPANY	303-1633-01 Remover, Roller Rocker Follower
Courtesy of FORD MOTOR COMPANY	303-1655 Tool, Camshaft Holding
Courtesy of FORD MOTOR COMPANY	303-335 (T88T-6701-A) Installer, Front Cover Oil Seal TKIT-1988-FLM TKIT-1988-F
Courtesy of FORD MOTOR COMPANY	307-399 Alignment Pins, Transmission Fluid Pump TKIT-2002N-DEW TKIT-2000AP-FLM/LM
Strap Wrench
Piston Ring Compressor

Materials 

1. Lubricate the piston cooling jets O-ring seal with clean engine oil.

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

   Courtesy of FORD MOTOR COMPANY

2. Install the piston cooling jets and bolts.

   Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 30°

   Courtesy of FORD MOTOR COMPANY

3. NOTE: This step is for selecting the correct rod bearings.
   • Record the rod bore grade code that is on the connecting rod.
   • Record the pin journal grade code that is on the crankshaft.
   • Match the connecting rod and the crankshaft with its corresponding column or row by reading across the crankshaft row and down the rod column in the next step.

   Courtesy of FORD MOTOR COMPANY

4. Connecting rod bearing grade chart.
   1. Crankshaft journal diameter.
   2. Rod bore diameter.
   • Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

   Courtesy of FORD MOTOR COMPANY

5. NOTE: This step is for selecting the correct main bearings.
   NOTE: The #1 main bearing is at the front of the engine block.
   • Select the crankshaft main bearings for each crankshaft journal.
   • Record the select fit code that is on the cylinder block face.
   • Record the main journal grade code that is on the crankshaft flange.
   • The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.

   Courtesy of FORD MOTOR COMPANY

6. NOTE: This chart is continued in the next step.
   NOTE: This chart is for selecting main bearings 1 and 4 only.
   • Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4.
   • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.
   • As an example, if the engine block code letter is "M" and the crankshaft code letter is "M", the correct bearing grade for this main bearing is a "2" for the upper bearing and a "2" for the lower bearing.
   • Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.

   Courtesy of FORD MOTOR COMPANY

7. NOTE: This chart is for selecting main bearings 1 and 4 only.

   Courtesy of FORD MOTOR COMPANY

8. NOTE: This chart is continued in the next step.
   NOTE: This chart is for selecting main bearings 2 and 3 only.
   • Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3.
   • Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.
   • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing.
   • As an example, if the engine block code letter is "N" and the crankshaft code letter is "H", the correct bearing grade for this main bearing is "2".
   • Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.

   Courtesy of FORD MOTOR COMPANY

9. NOTE: This chart is for selecting main bearings 2 and 3 only.

   Courtesy of FORD MOTOR COMPANY

10. 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.

    Lubricate the upper crankshaft main bearings with clean engine oil and install into the cylinder block.

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

    Courtesy of FORD MOTOR COMPANY

11. NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
    NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.

    Install the crankshaft.

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

    Courtesy of FORD MOTOR COMPANY

12. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

    Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.

    Courtesy of FORD MOTOR COMPANY

13. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

    Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.

    Courtesy of FORD MOTOR COMPANY

14. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Check seating and squareness of the bearings to make sure of proper seating in caps.

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

    Courtesy of FORD MOTOR COMPANY

15. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.

    Courtesy of FORD MOTOR COMPANY

16. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
    NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

    Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.

    Courtesy of FORD MOTOR COMPANY

17. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.

    Courtesy of FORD MOTOR COMPANY

18. NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.

    Tighten the main bearing bolts.

    Torque: Stage 1: 20 lb.ft (27 Nm) | Stage 2: 180°

    Fig 1: Main Bearing Cap Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
19. Install the new main bearing cap side bolts.

    Torque: Stage 1: 33 lb.ft (45 Nm) | Stage 2: 90°

    Fig 2: Main Bearing Cap Side Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
20. 1. Position the crankshaft to the rear of the cylinder block. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    2. Zero the Dial Indicator Gauge.
    3. Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play.

    Courtesy of FORD MOTOR COMPANY

21. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    • Prepare the connecting rod and cap
    • Insert the new bolts in the rod cap.
    • Insert the upper and lower rod bearings into the rod and cap.

    Courtesy of FORD MOTOR COMPANY

22. NOTE: This is for the RH pistons.
    NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring face pointing up toward the top of the piston.
    NOTE: The arrow on the top of the piston indicates the front of the engine.
    1. Center line of the piston parallel to the wrist pin bore.
    2. Upper compression ring gap location.

       PIP marks must be on top side of rings. 

    3. Upper oil control segment ring gap location.
    4. Lower oil control segment ring gap location.
    5. Lower compression ring gap location.

       Napier hook must be on bottom side of rings. 

    6. Spacer oil control ring gap location.

       Assemble with cut ends pointed up towards crown of piston. 

    Courtesy of FORD MOTOR COMPANY

23. NOTE: This is for the LH pistons.
    NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring face pointing up toward the top of the piston.
    NOTE: The arrow on the top of the piston indicates the front of the engine.
    1. Center line of the piston parallel to the wrist pin bore.
    2. Upper compression ring gap location.

       PIP marks must be on top side of rings. 

    3. Upper oil control segment ring gap location.
    4. Lower oil control segment ring gap location.
    5. Lower compression ring gap location.

       Napier hook must be on bottom side of rings. 

    6. Spacer oil control ring gap location.

       Assemble with cut ends pointed up towards crown of piston. 

    Courtesy of FORD MOTOR COMPANY

24. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Be sure not to damage or bend the piston oil cooling jets when seating the connecting rod on the crankshaft journal. 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. Refer to Piston .
    NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.
    NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.

    Using the Piston Ring Compressor and piston guide tool, install the piston and connecting rod assemblies. Repeat until all the piston assemblies are installed. Use the General Equipment: Piston Ring Compressor

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

    Courtesy of FORD MOTOR COMPANY

25. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation.
    NOTE: Lubricate the bolts with CP-Carrillo fastener assembly lube or equivalent.

    Install the connecting rod cap and the new bolts.

    Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 18 lb.ft (25 Nm) | Stage 3: 52°

    Courtesy of FORD MOTOR COMPANY

26. Install the main bearing cap support brace and the new bolts.

    Torque: Stage 1: 20 lb.ft (27 Nm) | Stage 2: 225°

    Fig 3: Main Bearing Cap Support Brace Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
27. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.

    Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    Courtesy of FORD MOTOR COMPANY

28. Lubricate the crankshaft rear seal with clean engine oil.

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

    Courtesy of FORD MOTOR COMPANY

29. Install the new crankshaft rear seal retainer and the bolts.

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

    Fig 4: Crankshaft Rear Seal Retainer Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
30. Install the CKP sensor and the bolt.

    Torque: 62 lb.in (7 Nm)

    Courtesy of FORD MOTOR COMPANY

31. Install the new oil manifold gasket.

    Courtesy of FORD MOTOR COMPANY

32. Install the oil manifold and the bolts.

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

    Courtesy of FORD MOTOR COMPANY

33. Install the oil transfer tube and filter O-ring seals and lubricate with clean engine oil.

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

    Courtesy of FORD MOTOR COMPANY

34. Install the oil transfer tube and filter with the flow arrow pointing towards the manifold.

    Courtesy of FORD MOTOR COMPANY

35. NOTE: The oil pan and the specified bolts must be installed and the oil pan aligned to the cylinder block within 10 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.
    NOTE: Do not go over a 3 mm (0.11 in) bead of sealant, there is a potential to obstruct cylinder head drainback passages.

    Apply a 3 mm (0.11 in) bead of sealant to the sealing surface of the oil pan.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    Courtesy of FORD MOTOR COMPANY

36. NOTE: The oil pan and the specified bolts must be installed and the oil pan aligned to the cylinder block within 10 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

    Apply a 5.5 mm (0.21 in) bead of sealant to the sealing surface of the oil pan.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    Courtesy of FORD MOTOR COMPANY

37. NOTE: The oil pan and the bolts must be installed within 10 minutes of the start of sealant application.
    • Align the oil transfer tube and filter and slide the oil pan on to oil transfer tube and alignment pin.
    • Install the alignment pin. Use Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
    • Install the oil pan bolts finger tight in sequence shown.

    Courtesy of FORD MOTOR COMPANY

38. Using a straight edge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.

    Courtesy of FORD MOTOR COMPANY

39. Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

    Courtesy of FORD MOTOR COMPANY

40. Install the remaining bolts finger tight and tighten the oil pan bolts in sequence shown.

    Torque: Stage 1: Tighten bolts 1 through 14 to: 177 lb.in (20 Nm) | Stage 2: Tighten bolts 1 through 14 an additional: 45° | Stage 3: Tighten bolts 15 through 16 to: 89 lb.in (10 Nm) | Stage 4: Tighten bolts 15 through 16 an additional: 45°

    Fig 5: Oil Pan Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
41. Install the coolant hose retainer bracket and the bolt.

    Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

42. Install a new channel cover plate gasket.

    Courtesy of FORD MOTOR COMPANY

43. Install the channel cover plate and the bolts and tighten in sequence shown.

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

    Fig 6: Channel Cover Plate Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
44. Install the KS and the bolts.

    Torque: 177 lb.in (20 Nm)

    Courtesy of FORD MOTOR COMPANY

45. Install the LH cylinder head gasket.

    Courtesy of FORD MOTOR COMPANY

46. Install the LH cylinder head and the new bolts.

    Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 33 lb.ft (45 Nm) | Stage 3: 90° | Stage 4: 90° | Stage 5: 90°

    Courtesy of FORD MOTOR COMPANY

47. Install the LH cylinder head M6 bolt.

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

    Courtesy of FORD MOTOR COMPANY

48. Install the RH cylinder head gasket.

    Courtesy of FORD MOTOR COMPANY

49. Install the RH cylinder head and the new bolts.

    Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 33 lb.ft (45 Nm) | Stage 3: 90° | Stage 4: 90° | Stage 5: 90°

    Courtesy of FORD MOTOR COMPANY

50. Install the RH cylinder head M6 bolt.

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

    Courtesy of FORD MOTOR COMPANY

51. Install the RH block coolant drain.

    Torque: Stage 1: 142 lb.in (16 Nm) | Stage 2: 180°

    Courtesy of FORD MOTOR COMPANY

52. Install the LH block coolant drain.

    Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 720°

    Courtesy of FORD MOTOR COMPANY

53. NOTE: Make sure that a new fuel rail to fuel rail high-pressure fuel tube is installed.
    NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas.

    Install the fuel rail to fuel rail high-pressure fuel tube and tighten the flare nuts finger tight and tighten the flare nuts in the following 3 stages.

    Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 89 lb.in (10 Nm) | Stage 3: 30°

    Courtesy of FORD MOTOR COMPANY

54. Install the fuel rail to fuel rail fuel supply line. Refer to: Spring Lock Couplings .

    Courtesy of FORD MOTOR COMPANY

55. Connect the secondary latches.

    Courtesy of FORD MOTOR COMPANY

56. NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.
    NOTE: If the original hydraulic lash adjusters are to be reinstalled, they must be installed in their original locations.
    1. Lubricate the hydraulic lash adjusters with clean engine oil.

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

    2. Install the RH hydraulic lash adjusters.

    Courtesy of FORD MOTOR COMPANY

57. NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.
    NOTE: If the original hydraulic lash adjusters are to be reinstalled, they must be installed in their original locations.
    1. Lubricate the hydraulic lash adjusters with clean engine oil.

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

    2. Install the LH hydraulic lash adjusters.

    Courtesy of FORD MOTOR COMPANY

58. Install the crankshaft sprocket.

    Courtesy of FORD MOTOR COMPANY

59. Install the original crankshaft pulley bolt.

    Courtesy of FORD MOTOR COMPANY

60. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

    Using the crankshaft bolt, rotate the crankshaft counterclockwise to the 9 o'clock position.

    Courtesy of FORD MOTOR COMPANY

61. NOTE: Coat the camshafts with clean engine oil prior to installation.

    Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral position as shown.

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

    Courtesy of FORD MOTOR COMPANY

62. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the RH camshaft seals gaps as shown.

    Courtesy of FORD MOTOR COMPANY

63. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    • Install camshaft bearing caps and the bolts.
    • Install camshaft bearing mega caps and the bolts.

      Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 45°

    Courtesy of FORD MOTOR COMPANY

64. Rotate the RH camshafts to TDC.

    Courtesy of FORD MOTOR COMPANY

65. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

    Courtesy of FORD MOTOR COMPANY

66. Position the RH VCT units onto the camshafts.

    Courtesy of FORD MOTOR COMPANY

67. Install the new RH VCT unit bolts.

    Torque: Stage 1: 30 lb.ft (40 Nm) | Stage 2: Loosen: 1 turn(s) | Stage 3: 18 lb.ft (25 Nm) | Stage 4: 150°

    Courtesy of FORD MOTOR COMPANY

68. NOTE: Coat the camshafts with clean engine oil prior to installation.

    Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral position as shown.

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

    Courtesy of FORD MOTOR COMPANY

69. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the LH camshaft seals gaps as shown.

    Courtesy of FORD MOTOR COMPANY

70. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    • Install camshaft bearing caps and the bolts.
    • Install camshaft bearing mega caps and the bolts.

      Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 45°

    Courtesy of FORD MOTOR COMPANY

71. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

    Courtesy of FORD MOTOR COMPANY

72. Position the LH VCT units onto the camshafts.

    Courtesy of FORD MOTOR COMPANY

73. Install the new LH VCT unit bolts.

    Torque: Stage 1: 30 lb.ft (40 Nm) | Stage 2: Loosen: 1 turn(s) | Stage 3: 18 lb.ft (25 Nm) | Stage 4: 150°

    Courtesy of FORD MOTOR COMPANY

74. Using the crankshaft bolt, rotate the crankshaft clockwise to the 11 o'clock position.

    Courtesy of FORD MOTOR COMPANY

75. Remove and discard the original crankshaft pulley bolt.

    Courtesy of FORD MOTOR COMPANY

76. 1. Install the LH timing chain with the single colored links aligned with the timing marks on the VCT units.
    2. Install the double colored links so they straddle the timing mark on the crankshaft sprocket.

    Courtesy of FORD MOTOR COMPANY

77. Install the LH timing chain guide and the bolts.

    Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

78. Install the LH timing chain tensioner arm.

    Courtesy of FORD MOTOR COMPANY

79. 1. Position the tensioner in a soft-jawed vise.
    2. Using pliers, squeeze the ends of the ratchet wire clip together.
    3. Using the soft-jawed vise, compress the plunger to the reset position.
    4. Install a locking pin in the 2 holes of the tensioner body to hold the plunger in place.

    Courtesy of FORD MOTOR COMPANY

80. 1. Position the LH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.
    2. Install the retainers.

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

    3. Remove the pin.

    Courtesy of FORD MOTOR COMPANY

81. 1. Install the RH timing chain with the single colored links aligned with the timing marks on the VCT units.
    2. Install the double colored links so they straddle the timing mark on the crankshaft sprocket.

    Courtesy of FORD MOTOR COMPANY

82. Install the RH timing chain guide and the bolts.

    Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

83. Install the RH timing chain tensioner arm.

    Courtesy of FORD MOTOR COMPANY

84. 1. Position the tensioner in a soft-jawed vise.
    2. Using pliers, squeeze the ends of the ratchet wire clip together.
    3. Using the soft-jawed vise, compress the plunger to the reset position.
    4. Install a locking pin in the 2 holes of the tensioner body to hold the plunger in place.

    Courtesy of FORD MOTOR COMPANY

85. 1. Position the RH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.
    2. Install the retainers.

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

    3. Remove the pin.

    Courtesy of FORD MOTOR COMPANY

86. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.

    Courtesy of FORD MOTOR COMPANY

87. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.

    Courtesy of FORD MOTOR COMPANY

88. Install the RH engine mount bracket and the new bolts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

89. NOTE: Make sure that the mating faces are clean and free of foreign material.

    Install the new gasket as shown with the single ridge facing up.

    Courtesy of FORD MOTOR COMPANY

90. NOTE: Make sure that the mating faces are clean and free of foreign material.

    Install a new O-ring seal.

    Courtesy of FORD MOTOR COMPANY

91. Prime the oil pump.
    1. Add 2.03 oz (60 cc) of clean engine oil to the oil pump inlet port.

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

    2. Add 0.5 oz (15 cc) of clean engine oil to the right hand turbo scavenge inlet port.

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

    3. Rotate oil pump pulley shaft counter clockwise 10 times by hand.

    Courtesy of FORD MOTOR COMPANY

92. Prime the scavenge oil pump.
    1. NOTE: Oil may flow out of the scavenge pump inlet port.

       Add 2.5 oz (75 cc) of clean engine oil to the scavenge pump discharge port.

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

    2. Rotate oil pump pulley shaft clockwise 10 times by hand.

    Courtesy of FORD MOTOR COMPANY

93. Prime the oil pump.
    • Hold the oil pump vertical with the shaft spline down for 10 seconds to internally wet the shaft seal.

    Courtesy of FORD MOTOR COMPANY

94. Clean the oil pump assembly exterior of any residual oil with isoprophyl alcohol before installation.

    Courtesy of FORD MOTOR COMPANY

95. Install the oil pump and tighten the bolts in sequence shown.

    Torque: 18 lb.ft (25 Nm)

    Fig 7: Oil Pump Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
96. Install the oil pump support bracket and the bolts.

    Torque: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

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

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

    Courtesy of FORD MOTOR COMPANY

98. Install the oil pump tube and the bolts.

    Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 30°

    Courtesy of FORD MOTOR COMPANY

99. Install a new cover plate gasket.

    Courtesy of FORD MOTOR COMPANY

100. Install the EOP sensor cover plate and the bolts.

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

     Courtesy of FORD MOTOR COMPANY

101. Install the RH engine mount bracket and the new bolts.

     Torque: 35 lb.ft (48 Nm)

     Courtesy of FORD MOTOR COMPANY

102. Using the special tools, install the front cover to coolant pipe seal. Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing, 205-153 (T80T-4000-W) Handle.

     Courtesy of FORD MOTOR COMPANY

103. Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

     Courtesy of FORD MOTOR COMPANY

104. • NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
       NOTE: The engine front cover and the 6 bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

       Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt boss.

       Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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105. • NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
       NOTE: The engine front cover and the 6 bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

       Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in places as indicated.

       Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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106. NOTE: Make sure the locating dowel pins are seated correctly in the cylinder block.

     Install the engine front cover and the bolts finger tight.

     Fig 8: Engine Front Cover Bolts Tightening Sequence

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107. Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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108. Install the remaining engine front cover bolts and tighten in the sequence shown in 3 stages.

     Torque: Stage 1: Tighten bolts 1 through 24 to: 89 lb.in (10 Nm) | Stage 2: Tighten bolts 1 through 24 to: 177 lb.in (20 Nm) | Stage 3: Tighten bolts 1 through 24 an additional: 45°

     Fig 9: Engine Front Cover Bolts Tightening Sequence

     Courtesy of FORD MOTOR COMPANY
109. Install the coolant hose retainer bracket and the nuts.

     Torque: 177 lb.in (20 Nm)

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110. Lubricate the crankshaft front seal bore with clean engine oil.

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

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111. Using the special tools, install the crankshaft front seal with the spring side towards the engine. Use Special Service Tool: 303-102 Installer, Crankshaft Pulley, 303-1251 Installer, Front Seal.

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112. Lubricate the crankshaft front seal with clean engine oil.

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

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113. Lubricate the crankshaft pulley with clean engine oil.

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

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114. Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal, 303-102 Installer, Crankshaft Pulley.

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115. Install the new crankshaft bolt and the washer. Use the General Equipment: Strap Wrench

     Torque: Stage 1: 89 lb.ft (120 Nm) | Stage 2: Loosen: 1 turn(s) | Stage 3: 37 lb.ft (50 Nm) | Stage 4: 150°

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116. Apply threadlock to the bolts and install the crankshaft pulley bolts.

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

     Torque: 24 lb.ft (32 Nm)

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117. Rotate the crankshaft pulley bolt clockwise to position the RH camshaft lobe upward for the camshaft roller follower to be installed.

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118. 1. Install Special Service Tool: 303-1633 Remover, Roller Rocker Follower, 303-1633-01 Remover, Roller Rocker Follower.
     2. Turn the knob on the special tool clockwise to depress the valve and spring.

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119. 1. Lubricate the camshaft roller follower with clean engine oil.

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

     2. Install the camshaft roller follower.
     3. Assemble the camshaft roller follower spring clip onto the hydraulic lash adjuster.
     4. Turn the knob on the special tool counterclockwise to raise the valve and spring. Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower, 303-1633-01 Remover, Roller Rocker Follower.
     5. Repeat steps for the remaining camshaft roller followers.

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120. Rotate the crankshaft pulley bolt clockwise to position the LH camshaft lobe upward for the camshaft roller follower to be installed.

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121. 1. Install Special Service Tool: 303-1633 Remover, Roller Rocker Follower.
     2. Turn the knob on the special tool clockwise to depress the valve and spring.

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122. 1. Lubricate the camshaft roller follower with clean engine oil.

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

     2. Install the camshaft roller follower.
     3. Assemble the camshaft roller follower spring clip onto the hydraulic lash adjuster.
     4. Turn the knob on the special tool counterclockwise to raise the valve and spring. Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower.
     5. Repeat steps for the remaining camshaft roller followers.

     Courtesy of FORD MOTOR COMPANY

123. • Install a new coolant pump gasket.
     • Install a new O-ring seal and lubricate with clean engine coolant.

       Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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124. Install the coolant pump and the bolts.

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

     Fig 10: Coolant Pump Bolts Tightening Sequence

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125. Install the coolant pump belt idler pulley bracket and the bolts.

     Torque: 18 lb.ft (25 Nm)

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126. Install the coolant pump belt idler pulley and the bolts.

     Torque: 18 lb.ft (25 Nm)

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127. Install a new coolant pump belt.

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128. NOTE: Installation of new seals is only required if damaged seals were removed.

     If removed, using the special tools, install the spark plug tube seals. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer, 205-153 (T80T-4000-W) Handle.

     Courtesy of FORD MOTOR COMPANY

129. NOTE: Installation of new seals is only required if damaged seals were removed.

     If removed, using the special tools, install the VCT oil control solenoid seals. Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone, 205-153 (T80T-4000-W) Handle.

     Courtesy of FORD MOTOR COMPANY

130. Install a new RH valve cover gasket.

     Courtesy of FORD MOTOR COMPANY

131. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned.

     Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to- RH cylinder head joints.

     Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

     Courtesy of FORD MOTOR COMPANY

132. Install the RH valve cover and tighten the fasteners.

     Torque: 89 lb.in (10 Nm)

     Fig 11: RH Valve Cover Bolts Tightening Sequence

     Courtesy of FORD MOTOR COMPANY
133. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.

     Courtesy of FORD MOTOR COMPANY

134. NOTE: Installation of new seals is only required if damaged seals were removed.

     If removed, using the special tools, install the spark plug tube seals. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer, 205-153 (T80T-4000-W) Handle.

     Courtesy of FORD MOTOR COMPANY

135. NOTE: Installation of new seals is only required if damaged seals were removed.

     If removed, using the special tools, install the VCT oil control solenoid seals. Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone, 205-153 (T80T-4000-W) Handle.

     Courtesy of FORD MOTOR COMPANY

136. Install a new LH valve cover gasket.

     Courtesy of FORD MOTOR COMPANY

137. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned.

     Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to- LH cylinder head joints.

     Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

     Courtesy of FORD MOTOR COMPANY

138. Install the LH valve cover and tighten the fasteners.

     Torque: 89 lb.in (10 Nm)

     Fig 12: LH Valve Cover Bolts Tightening Sequence

     Courtesy of FORD MOTOR COMPANY
139. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.

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140. Inspect the ignition coil-on-plugs. Replace any damaged ignition coil-on-plugs. Replace any of the ignition coil-on-plug boots with cracks, rips or tears.

     Courtesy of FORD MOTOR COMPANY

141. Install the LH ignition coil-on-plugs and the bolts.

     Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 50°

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142. Install the RH ignition coil-on-plugs and the bolts.

     Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 50°

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143. NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.
     NOTE: The drive lobe for the high-pressure fuel pump must be at BDC (bottom dead center) for the high-pressure fuel pump installation.

     Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC.

     Courtesy of FORD MOTOR COMPANY

144. Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and the roller tappet. Install the high-pressure fuel pump roller tappet.

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

     Courtesy of FORD MOTOR COMPANY

145. • Inspect the high-pressure fuel pump mounting plate seal and replace as needed.
     • Lubricate the mounting plate seal with clean engine oil.

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

     Courtesy of FORD MOTOR COMPANY

146. Install a new high-pressure fuel pump O-ring seal and lubricate with clean engine oil.

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

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147. • Inspect the high-pressure fuel pump mounting plate O-ring seals and replace as needed.
     • Lubricate the mounting plate O-ring seals with clean engine oil.

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

     Courtesy of FORD MOTOR COMPANY

148. Install the high-pressure fuel pump mounting plate on to the high-pressure fuel pump and install the high-pressure fuel pump bolts.

     Courtesy of FORD MOTOR COMPANY

149. 1. Install the high-pressure fuel pump with the mounting plate and install and finger tighten the high-pressure fuel pump bolts. Finger tighten the mounting plate bolt. Alternately tighten each high-pressure fuel pump bolt one complete revolution until seated. Tighten the fuel high-pressure fuel pump bolts in the following 2 stages.

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

     2. Tighten the high-pressure fuel pump mounting plate bolt.

        Torque: 89 lb.in (10 Nm)

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150. 1. Install the high-pressure fuel pump to fuel rail high-pressure fuel tube and tighten the flare nuts finger tight.
     2. Install the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts finger tight.
     3. Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube flare nuts.

        Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 89 lb.in (10 Nm) | Stage 3: 30°

     4. Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts.

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

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151. Install the high-pressure fuel pump supply line and connect the spring lock couplings and retainers. Refer to: Spring Lock Couplings .

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152. Connect the secondary latches.

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153. Install the fuel inlet tube. Refer to: Quick Release Coupling .

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154. • Install the engine wiring harness and attach the wiring harness retainers.
     • Connect the high pressure fuel pump electrical connector.
     • Connect the VCT unit electrical connectors.
     • Connect the ignition coil-on-plug electrical connectors.

     Courtesy of FORD MOTOR COMPANY

155. • Install the ground wire and the stud bolt.

       Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 20°

     • Connect the port injector fuel rail harness electrical connectors.
     • Connect the KS sensor electrical connector.

     Courtesy of FORD MOTOR COMPANY

156. • Position the wiring harness and attach the wiring harness retainers.
     • Connect the CHT sensor electrical connectors.
     • Connect the CMP sensor electrical connectors.
     • Connect the direct injector fuel rail harness electrical connectors.

     Courtesy of FORD MOTOR COMPANY

157. Install the heat shield and the retainers.

     Torque: Stage 1: 97 lb.in (11 Nm) | Stage 2: 20°

     Courtesy of FORD MOTOR COMPANY

158. • Position the wiring harness and attach the wiring harness retainers.
     • Connect the VCT unit electrical connectors.
     • Connect the CMP sensor electrical connectors.
     • Connect the ignition coil-on-plug electrical connectors.

     Courtesy of FORD MOTOR COMPANY

159. Install the ground wire and the stud bolt.

     Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 20°

     Courtesy of FORD MOTOR COMPANY

160. • Attach the wiring harness retainer.
     • Connect the CKP sensor wiring harness electrical connector.
     • Install the CKP sensor cover.
     • Install the wiring harness retainer bolt.

       Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 20°

     Courtesy of FORD MOTOR COMPANY

161. Connect the EOP sensor wiring harness electrical connector and retainer.

     Courtesy of FORD MOTOR COMPANY

162. • Install a new thermostat housing gasket.
     • Lubricate the thermostat housing O-ring seal with clean engine coolant.

     Courtesy of FORD MOTOR COMPANY

163. Install the thermostat housing and hoses and the bolts.

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

     Courtesy of FORD MOTOR COMPANY

164. Position the coolant hoses and retainer and install the nut.

     Torque: 89 lb.in (10 Nm)

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165. Install the coolant hoses and tighten the clamps.

     Torque: 44 lb.in (5 Nm)

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166. • Install the coolant hose retainer nut.

       Torque: 97 lb.in (11 Nm)

     • Attach the coolant hose retainer.
     • Install the coolant hose retainer nut and bolt.

       Torque: 97 lb.in (11 Nm)

     Courtesy of FORD MOTOR COMPANY

167. Connect the coolant hoses and tighten the clamps.

     Torque: 44 lb.in (5 Nm)

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168. • Install the coolant hoses and tighten the coolant hose clamps.

       Torque: 44 lb.in (5 Nm)

     • Install and tighten the coolant hose fitting.

       Torque: 97 lb.in (11 Nm)

Courtesy of FORD MOTOR COMPANY