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Engine 3.5L GTDI: Assembly: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) 

GFD231246Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
GFD231366Courtesy of FORD MOTOR COMPANY
 Alignment Pins 307-399
GFD231367Courtesy of FORD MOTOR COMPANY
 Brush, Fuel Injector 310-205
GFD231368Courtesy of FORD MOTOR COMPANY
 Compressor, Piston Ring 303-D032 (D81L-6002-C)
GFD231369Courtesy of FORD MOTOR COMPANY
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GFD231249Courtesy of FORD MOTOR COMPANY
 Engine Lift Eye 303-1245
GFD231114Courtesy of FORD MOTOR COMPANY
 Handle 205-153 (T80T-4000-W)
GFD231370Courtesy of FORD MOTOR COMPANY
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
GFD231371Courtesy of FORD MOTOR COMPANY
 Installer, Front Cover Oil Seal 303-335
GFD231372Courtesy of FORD MOTOR COMPANY
 Installer, Front Crankshaft Seal 303-1251
GFD231373Courtesy of FORD MOTOR COMPANY
 Installer, VCT Spark Plug Tube Seal 303-1247/2
GFD231374Courtesy of FORD MOTOR COMPANY
 Seal Installer, Fuel Injector 310-207
GFD231250Courtesy of FORD MOTOR COMPANY
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GFD231118Courtesy of FORD MOTOR COMPANY
 Strap Wrench 303-D055 (D85L-6000-A) or equivalent
GFD231119Courtesy of FORD MOTOR COMPANY
 Tool, Camshaft Holding 303-1248

Material 

Item Specification
Motorcraft ® High Performance Engine RTV Silicone TA-357 WSE-M4G323-A6
Motorcraft ® Metal Surface Prep Wipes ZC-31-B -
Motorcraft ® SAE 5W-30 Synthetic Blend Motor Oil (US); Motorcraft ® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada) WSS-M2C946-A
Motorcraft ® Silicone Gasket Remover ZC-30-A -
Motorcraft ® Orange Concentrated Antifreeze/Coolant VC-3-B (US); CVC-3-B2 (Canada) WSS-M97B44-D
Motorcraft ® Thread Sealant with PTFETA-24-B WSK-M2G350-A2
Motorcraft ® Threadlock and Sealer TA-25-B WSK-M2G351-A5

Engine Upper 

GFD231375Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 12C508 Engine control harness
2 9425 Intake manifold
3 8594 Thermostat housing
4 9D280 Fuel rail
5 9N271 Coolant tube
6 12A699 Knock Sensor (KS)
7 6010 Cylinder block

Engine Upper - LH Cylinder Head 

GFD231376Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 9429 Exhaust manifold
2 6083 LH cylinder head gasket
3 6C261 LH Variable Camshaft Timing (VCT) housing
4 W712244 LH exhaust manifold stud (8 required)
5 6050 LH cylinder head
6 6500 Valve tappet (32 required)
7 6C271 LH secondary timing chain tensioner
8 6279 LH camshaft bolt (2 required)
9 W710738 LH exhaust camshaft sprocket washer
10 6C524 LH VCT assembly
11 6C256 LH secondary timing chain
12 6256 LH exhaust camshaft sprocket
13 6A269 LH exhaust camshaft
14 6A267 LH intake camshaft
15 6A258 LH camshaft cap (4 required)
16 6B281 LH camshaft cap (2 required)
17 6B287 LH camshaft cap
18 6750 Oil level indicator
19 6A505 LH valve cover
20 9178 Fuel injection pump mounting plate
21 9D376 Fuel injection pump

Engine Upper - RH Cylinder Head 

GFD231377Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 W712244 RH exhaust manifold stud (8 required)
2 6051 RH cylinder head gasket
3 6049 RH cylinder head
4 6G004 Cylinder Head Temperature (CHT) sensor
5 12K073 Camshaft Position (CMP) sensor (2 required)
6 17A084 Engine lift eye
7 6C260 RH Variable Camshaft Timing (VCT) housing
8 6C270 RH secondary timing chain tensioner
9 6279 RH camshaft bolt (2 required)
10 W710738 RH exhaust camshaft sprocket washer
11 6256 RH exhaust camshaft sprocket
12 6C524 RH VCT assembly
13 6C256 RH secondary timing chain
14 6A266 RH intake camshaft
15 12405 Spark plug (6 required)
16 6A258 RH camshaft cap (6 required)
17 6A268 RH exhaust camshaft
18 6B280 RH camshaft cap (2 required)
19 6582 RH valve cover
20 12A375 Ignition coil-on-plug (6 required)

Engine Front 

GFD231378Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 6A0003 Engine mount bracket
2 W701512 Crankshaft pulley bolt
3 N806165 Crankshaft pulley washer
4 6316 Crankshaft pulley
5 6700 Crankshaft front seal
6 6C086 Engine front cover

Timing Drive Components 

GFD231379Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 6268 Timing chain
2 6306 Crankshaft timing sprocket
3 6K254 Primary timing chain tensioner
4 6K255 Primary timing chain tensioner arm
5 6B274 LH lower primary timing chain guide
6 6M256 RH primary timing chain guide
7 6K297 LH upper primary timing chain guide
8 8501 Coolant pump

Lower Engine Block (View 1) 

GFD231380Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 6675 Oil pan
2 6622 Oil pump screen and pickup tube
3 6625 Oil pump screen and pickup tube O-ring seal
4 6621 Oil pump
5 6010 Cylinder block
6 6D327 Crankshaft rear seal retainer
7 12A227 Crankshaft sensor ring
8 6375 Flexplate
9 6881 Oil filter adapter
10 9278 Engine Oil Pressure (EOP) switch
11 6714 Engine oil filter

Lower Engine Block (View 2) 

GFD231381Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 - Piston compression upper ring (part of 6148) (6 required)
2 - Piston compression lower ring (part of 6148) (6 required)
3 - Piston oil control upper segment ring (part of 6148) (6 required)
4 - Piston oil control spacer (part of 6148) (6 required)
5 - Piston oil control lower segment ring (part of 6148) (6 required)
6 6140 Piston pin retainer (12 required)
7 6135 Piston pin (6 required)
8 6110 Piston (6 required)
9 6200 Connecting rod (6 required)
10 6211 Connecting rod upper bearing (6 required)
11 6211 Connecting rod lower bearing (6 required)
12 - Connecting rod cap (part of 6200) (6 required)
13 6010 Cylinder block
14 6A341 Crankshaft upper thrust washer (2 required)
15 6333 Cylinder block crankshaft main bearing (4 required)
16 6303 Crankshaft
17 6K302 Crankshaft lower thrust washer
18 6333 Lower crankshaft main bearings (4 required)
19 - Lower crankshaft main bearing caps (part of 6010) (4 required)
20 6C364 Main bearing cap support brace
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System General Information .
  1. 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 code that is on the cylinder block face.
    • Record the 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.

    GFD231382Courtesy of FORD MOTOR COMPANY
  2. 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.

    GFD231383Courtesy of FORD MOTOR COMPANY
  3. NOTE: This chart is for selecting main bearings 1 and 4 only.
    GFD231384Courtesy of FORD MOTOR COMPANY
  4. 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.

    GFD231385Courtesy of FORD MOTOR COMPANY
  5. NOTE: This chart is for selecting main bearings 2 and 3 only.
    GFD231386Courtesy of FORD MOTOR COMPANY
  6. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Using the original connecting rod cap bolts, install the connecting rod caps and bolts.

    • Tighten the bolts in 3 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.

  7. Measure the connecting rod large end bore in 2 directions.

    • Remove the bolts and the rod cap.

      • Discard the connecting rod cap bolts.

    GFD231387Courtesy of FORD MOTOR COMPANY
  8. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
    GFD231388Courtesy of FORD MOTOR COMPANY
  9. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    GFD231389Courtesy 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 the 4 crankshaft main bearings in the cylinder block.

    GFD231364Courtesy 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 onto the upper main bearings.

    GFD231362Courtesy 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.

    GFD231390Courtesy 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.

    GFD231391Courtesy of FORD MOTOR COMPANY
  14. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.
    GFD231365Courtesy of FORD MOTOR COMPANY
  15. NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engine have a 15 mm bolt head with fine threads for the main bearing caps.
    NOTE: Early build engine shown, late build engine similar.

    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.

    GFD231392Courtesy 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.

    GFD231393Courtesy of FORD MOTOR COMPANY
  17. NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engine have a 15 mm bolt head with fine threads for the main bearing caps.
    NOTE: Early build engine shown, late build engine similar.

    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.

    GFD231394Courtesy of FORD MOTOR COMPANY
  18. Loosen the No. 4 main bearing cap bolts.
  19. NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engine have a 15 mm bolt head with fine threads for the main bearing caps.
    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.
    NOTE: Early build engine shown, late build engine similar.

    Tighten the main bearing bolts in the sequence shown in 2 stages.

    • Early build engines - Stage 1: Tighten fasteners 1 through 8 to 33 Nm (24 lb-ft).
    • Early build engines - Stage 2: Tighten fasteners 1 through 8 an additional 135 degrees.
    • Late build engines - Stage 1: Tighten fasteners 1 through 8 to 27 Nm (20 lb-ft).
    • Late build engines - Stage 2: Tighten fasteners 1 through 8 an additional 180 degrees.

    Fig 1: Main Bearing Cap Bolt Tightening Sequence
    GFD231395Courtesy of FORD MOTOR CO.
  20. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in 2 stages.

    • Stage 1: Tighten fasteners 1 through 8 to 45 Nm (33 lb-ft).
    • Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.

    Fig 2: Main Bearing Cap Side Bolt Tightening Sequence
    GFD231396Courtesy of FORD MOTOR CO.
  21. 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.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.

    GFD231397Courtesy of FORD MOTOR COMPANY
  22. 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.

    GFD231398Courtesy of FORD MOTOR COMPANY
  23. Before installing the pistons into the cylinder block, verify proper ring gap location.

    1. Center line of the piston parallel to the wrist pin bore
    2. Upper compression ring gap location
    3. Upper oil control segment ring gap location
    4. Lower oil control segment ring gap location
    5. Expander ring and lower compression ring gap location

    GFD231399Courtesy of FORD MOTOR COMPANY
  24. 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: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown.
    NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
    NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to Disassembly and Assembly of Subassemblies - Piston .
    NOTE: 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, install the piston and connecting rod assemblies.

    GFD231400Courtesy of FORD MOTOR COMPANY
  25. Seat the connecting rod on the crankshaft journal.
  26. 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.

    Install the connecting rod cap and bolts.

    • Tighten the bolts in 3 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.

    GFD231401Courtesy of FORD MOTOR COMPANY
  27. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
  28. NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engine have a 15 mm bolt head with fine threads for the main bearing caps.
    NOTE: Early build engine shown, late build engine similar.

    Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in 2 steps.

    • Early build engines - Stage 1: Tighten fasteners 1 through 8 to 24 Nm (18 lb-ft).
    • Early build engines - Stage 2: Tighten fasteners 1 through 8 an additional 180 degrees.
    • Late build engines - Stage 1: Tighten fasteners 1 through 8 to 27 Nm (20 lb-ft).
    • Late build engines - Stage 2: Tighten fasteners 1 through 8 an additional 225 degrees.

    Fig 3: Main Bearing Cap Support Brace Bolt Tightening Sequence
    GFD231402Courtesy of FORD MOTOR CO.
  29. 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 10 minutes of sealant application.
    NOTE: The stamped steel crankshaft rear seal retainer plate comes with the crankshaft rear seal.

    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.

    GFD231403Courtesy of FORD MOTOR COMPANY
  30. NOTE: Lubricate the crankshaft rear seal with clean engine oil.

    Install the crankshaft rear seal retainer and the 8 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    Fig 4: Crankshaft Rear Seal Retainer Bolt Tightening Sequence
    GFD231404Courtesy of FORD MOTOR CO.
  31. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
  32. Install the oil pump and the 3 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD231355Courtesy of FORD MOTOR COMPANY
  33. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD231354Courtesy of FORD MOTOR COMPANY
  34. NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.
    NOTE: The rear A/C compressor stud bolt was removed in engine removal.

    Install the A/C compressor and the 2 stud bolts.

    • Tighten to 25 Nm (18 lb-ft).

    GFD231405Courtesy of FORD MOTOR COMPANY
  35. 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 oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 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 oil pan.

    GFD231406Courtesy of FORD MOTOR COMPANY
  36. Apply a 5.5 mm (0.21 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
    GFD231407Courtesy of FORD MOTOR COMPANY
  37. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

    Install the oil pan and bolts 10, 11, 13 and 14.

    • Tighten the bolts in the sequence shown to 3 Nm (27 lb-in).
    • Loosen the bolts 180 degrees.

    GFD231408Courtesy of FORD MOTOR COMPANY
  38. Align the oil pan to the cylinder block and A/C compressor.

    • Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.

    GFD231409Courtesy of FORD MOTOR COMPANY
  39. Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 Nm (27 lb-in).
    GFD231410Courtesy of FORD MOTOR COMPANY
  40. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown.

    • Tighten the large bolts (1-14) to 24 Nm (18 lb-ft).
    • Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).

    GFD231411Courtesy of FORD MOTOR COMPANY
  41. Install the A/C compressor mounting stud, Catalyst Monitor Sensor (CMS) electrical connector bracket and nut.

    • Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).

    GFD231412Courtesy of FORD MOTOR COMPANY
  42. NOTE: This stud bolt will be reinstalled during engine installation.

    Remove the rear A/C compressor stud bolt.

    GFD231413Courtesy of FORD MOTOR COMPANY
  43. Install the coolant pump and the 8 bolts. Tighten in the sequence shown in 2 stages:

    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

    Fig 5: Coolant Pump Bolt Tightening Sequence
    GFD231414Courtesy of FORD MOTOR CO.
  44. Install the Knock Sensor (KS) and the 2 bolts.

    • Tighten to 20 Nm (177 lb-in).

    GFD231350Courtesy of FORD MOTOR COMPANY
  45. NOTE: Apply clean engine coolant to the O-ring seal prior to installation.

    Using new O-ring seal, install the coolant inlet tube.

    GFD231349Courtesy of FORD MOTOR COMPANY
  46. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 45 degrees.

    GFD231415Courtesy of FORD MOTOR COMPANY
  47. Install the M6 bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231416Courtesy of FORD MOTOR COMPANY
  48. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 45 degrees.

    GFD231417Courtesy of FORD MOTOR COMPANY
  49. Install the M6 bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231347Courtesy of FORD MOTOR COMPANY
  50. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

    Position the crankshaft dowel pin in the 9 o'clock position.

    GFD231418Courtesy of FORD MOTOR COMPANY
  51. NOTE: The valve tappets must be installed in their original positions.
    NOTE: Coat the valve tappets with clean engine oil prior to installation.
    NOTE: LH shown, RH similar.

    Install the valve tappets.

    GFD231346Courtesy of FORD MOTOR COMPANY
  52. NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur.
    NOTE: Coat the camshafts with clean engine oil prior to installation.

    Position the camshafts onto the RH cylinder head in the neutral position as shown.

    GFD231419Courtesy of FORD MOTOR COMPANY
  53. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following stages:

    • Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).
    • Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 4: Loosen bolts 5 and 6.
      • Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).
    • Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 8: Loosen bolts 13 and 14.
      • Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.

    Fig 6: RH Camshaft Cap Bolt Tightening Sequence
    GFD231420Courtesy of FORD MOTOR CO.
  54. NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur.
    NOTE: Coat the camshafts with clean engine oil prior to installation.

    Position the camshafts onto the LH cylinder head in the neutral position as shown.

    GFD231421Courtesy of FORD MOTOR COMPANY
  55. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following stages:

    • Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).
    • Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 4: Loosen bolts 5 and 6.
      • Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).
    • Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.
    • Stage 8: Loosen bolts 13 and 14.
      • Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.

    Fig 7: LH Camshaft Cap Bolt Tightening Sequence
    GFD231422Courtesy of FORD MOTOR CO.
  56. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to Valve Clearance Check .

    GFD231423Courtesy of FORD MOTOR COMPANY
  57. Install the RH timing chain guide and bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231345Courtesy of FORD MOTOR COMPANY
  58. Install the RH secondary timing chain tensioner and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD231344Courtesy of FORD MOTOR COMPANY
  59. NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Rotate the RH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.

    GFD231424Courtesy of FORD MOTOR COMPANY
  60. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.

    • Align the colored links with the timing marks.

    GFD231425Courtesy of FORD MOTOR COMPANY
  61. Position the RH secondary timing assembly onto the camshafts.
    GFD231426Courtesy of FORD MOTOR COMPANY
  62. Install the new VCT bolt and the exhaust camshaft bolt and the original washer. Tighten in 4 stages.

    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 10 Nm (89 lb-in).
    • Stage 4: Tighten 90 degrees.

    GFD231242Courtesy of FORD MOTOR COMPANY
  63. Remove the lockpin from the RH secondary timing chain tensioner.
    GFD231427Courtesy of FORD MOTOR COMPANY
  64. Install the LH secondary timing chain tensioner and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD231343Courtesy of FORD MOTOR COMPANY
  65. NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Rotate the LH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of the camshafts.

    GFD231428Courtesy of FORD MOTOR COMPANY
  66. NOTE: Only the LH intake camshaft has a shim.

    Install the LH intake camshaft shim.

    GFD231237Courtesy of FORD MOTOR COMPANY
  67. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.

    • Align the colored links with the timing marks.

    GFD231429Courtesy of FORD MOTOR COMPANY
  68. Position the LH secondary timing assembly onto the camshafts.
    GFD231430Courtesy of FORD MOTOR COMPANY
  69. Install the new VCT bolt and the exhaust camshaft bolt and the original washer. Tighten in 4 stages.

    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 10 Nm (89 lb-in).
    • Stage 4: Tighten 90 degrees.

    GFD231236Courtesy of FORD MOTOR COMPANY
  70. Remove the lockpin from the LH secondary timing chain tensioner.
    GFD231431Courtesy of FORD MOTOR COMPANY
  71. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
    GFD231432Courtesy of FORD MOTOR COMPANY
  72. Install the crankshaft timing chain sprocket.
    GFD231341Courtesy of FORD MOTOR COMPANY
  73. Install the upper LH primary timing chain guide and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231342Courtesy of FORD MOTOR COMPANY
  74. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.

    Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.

    GFD231433Courtesy of FORD MOTOR COMPANY
  75. Install the lower LH primary timing chain guide and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD231233Courtesy of FORD MOTOR COMPANY
  76. Install the primary timing chain tensioner arm.
    GFD231232Courtesy of FORD MOTOR COMPANY
  77. Reset the primary timing chain tensioner.

    1. Release the ratchet detent.
    2. Using a soft-jawed vise, compress the ratchet plunger.
    3. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a suitable lockpin.

    GFD231434Courtesy of FORD MOTOR COMPANY
  78. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.

    Install the primary tensioner and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.

    GFD231435Courtesy of FORD MOTOR COMPANY
  79. As a post-check, verify correct alignment of all timing marks.

    • There are 48 links between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
    • There are 35 links between the LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket colored links (3).

    GFD231436Courtesy of FORD MOTOR COMPANY
  80. Inspect the VCT housing seals for damage and replace as necessary.
    GFD231437Courtesy of FORD MOTOR COMPANY
  81. NOTE: RH shown, LH similar.
    NOTE: During removal, the O-ring seal may remain on the cylinder head. If so, remove the O-ring seal from the cylinder head, inspect the seal (replace as necessary) and install the O-ring seal on the VCT housing.

    Inspect the VCT housing-to-cylinder head O-ring seals for damage and replace as necessary.

    GFD231438Courtesy of FORD MOTOR COMPANY
  82. NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this instruction will result in severe engine damage.

    Install the LH VCT housing and the 3 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    GFD231439Courtesy of FORD MOTOR COMPANY
  83. NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this instruction will result in severe engine damage.

    Install the RH VCT housing and the 3 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    GFD231440Courtesy of FORD MOTOR COMPANY
  84. Install the Alignment Pins.
    GFD231441Courtesy of FORD MOTOR COMPANY
  85. 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 bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket 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 these instructions 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 3 engine mount bracket bosses.

    • 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 5 places as indicated.

    GFD231442Courtesy of FORD MOTOR COMPANY
  86. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

    Install the engine front cover and bolts 17, 18, 19 and 20.

    • Tighten in sequence to 3 Nm (27 lb-in).

    GFD231443Courtesy of FORD MOTOR COMPANY
  87. Remove the Alignment Pins.
    GFD231444Courtesy of FORD MOTOR COMPANY
  88. NOTE: Do not tighten the bolts at this time.

    Install the engine mount bracket and the 3 bolts.

    GFD231220Courtesy of FORD MOTOR COMPANY
  89. NOTE: Do not expose the Motorcraft ® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

    Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:

    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).

    GFD231445Courtesy of FORD MOTOR COMPANY
  90. NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.

    Install the engine mount studs in the following sequence.

    1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
    2. Clean all the thread sealer from the engine mount studs (old and new studs).
    3. Apply new Threadlock and Sealer to the engine mount stud threads.
    4. Install the 2 engine mount studs.

      • Tighten to 20 Nm (177 lb-in).

    GFD231446Courtesy of FORD MOTOR COMPANY
  91. Install the Heated Oxygen Sensor (HO2S) connector bracket and bolt to the engine front cover.

    • Tighten to 10 Nm (89 lb-in).

    GFD231219Courtesy of FORD MOTOR COMPANY
  92. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

    Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.

    GFD231447Courtesy of FORD MOTOR COMPANY
  93. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

    Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.

    GFD231448Courtesy of FORD MOTOR COMPANY
  94. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.

    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.

    GFD231449Courtesy of FORD MOTOR COMPANY
  95. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
    NOTE: Spark plug tube seal installation shown, VCT solenoid seal installation similar.

    Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.

    GFD231450Courtesy of FORD MOTOR COMPANY
  96. 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: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow these instructions can cause future oil leakage.

    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.

    GFD231451Courtesy of FORD MOTOR COMPANY
  97. Using a new gasket, install the RH valve cover. Tighten the 6 stud bolts and the 5 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    GFD231452Courtesy of FORD MOTOR COMPANY
  98. 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: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow these instructions can cause future oil leakage.

    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.

    GFD231453Courtesy of FORD MOTOR COMPANY
  99. Using a new gasket, install the LH valve cover. Tighten the 10 stud bolts and the bolt.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    GFD231454Courtesy of FORD MOTOR COMPANY
  100. Install the 3 LH ignition coil-on-plugs and the 3 bolts.

    • Tighten to 7 Nm (62 lb-in).

    GFD231209Courtesy of FORD MOTOR COMPANY
  101. Install the 3 RH ignition coil-on-plugs and the 3 bolts.

    • Tighten to 7 Nm (62 lb-in).

    GFD231210Courtesy of FORD MOTOR COMPANY
  102. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

    Using the Fuel Injector Brush, clean the fuel injector orifices.

    GFD231455Courtesy of FORD MOTOR COMPANY
  103. NOTE: Do not attempt to cut the lower Teflon ® seal without first pulling it away from the fuel injector or damage to the injector may occur.
    NOTE: Be very careful when removing the lower Teflon ® seals, not to scratch, nick or gouge the fuel injectors.

    Pull the Teflon ® seal away from the injector with narrow tip pliers.

    GFD231456Courtesy of FORD MOTOR COMPANY
  104. Carefully cut and remove the 6 lower fuel injector Teflon ® seals.

    • Discard the 6 lower fuel injector Teflon ® seals.

    GFD231457Courtesy of FORD MOTOR COMPANY
  105. NOTE: Do not lubricate the 6 new lower Teflon ® fuel injector seals.
    NOTE: The original lower Teflon ® fuel injector seals may be either black or white. When installing new seals, always use the black Teflon ® fuel injector seals.

    Install the new Teflon ® seals on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tips.

    GFD231458Courtesy of FORD MOTOR COMPANY
  106. Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon ® seals off of the Arbor and into the groove on the fuel injectors.
    GFD231459Courtesy of FORD MOTOR COMPANY
  107. Place the Adjustment Ring (part of the Fuel Injector Seal Installer) beveled side first, over the fuel injector tip until it bottoms out against the fuel injector and turn 180 degrees.

    • After one minute, turn the Adjustment Ring back 180 degrees and remove.

    GFD231460Courtesy of FORD MOTOR COMPANY
  108. NOTE: It is very important to note the routing of the fuel charge wiring harnesses on the fuel rails and index-mark the location of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct fuel charge wire harness routing and tie strap positioning for installation.

    Install the fuel charge wire harnesses and tie straps to the index-marked locations on the fuel rails. Start by attaching the first tie strap farthest down the wire harness and continue to the connector end of the harness, leaving ample slack between the fuel injectors.

    GFD231334Courtesy of FORD MOTOR COMPANY
  109. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: To install, apply clean engine oil to the 6 new upper fuel injector O-ring seals only. Do not lubricate the lower fuel injector Teflon ® seals.
    NOTE: Inspect the fuel injector support disks and replace if necessary.

    Install the 6 new upper fuel injector O-ring seals.

    GFD231338Courtesy of FORD MOTOR COMPANY
  110. Install the 6 new fuel injector clips.
    GFD231339Courtesy of FORD MOTOR COMPANY
  111. NOTE: RH shown, LH similar.
    NOTE: The anti rotation device on the fuel injector has to slip into the groove of the fuel rail cup.

    Install the 6 fuel injectors into the fuel rails and connect the 6 electrical connectors.

    GFD231461Courtesy of FORD MOTOR COMPANY
  112. NOTE: It is very important to visually inspect the routing of the wire harness to make sure that the wire harness will not be pinched or damaged between the fuel rail and the cylinder head during installation.

    Install the 6 bolts and the RH fuel rail assembly.

    • Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and then proceed inward.
    • To install, tighten to 10 Nm (89 lb-in).
    • Tighten an additional 45 degrees.

    GFD231462Courtesy of FORD MOTOR COMPANY
  113. NOTE: It is very important to visually inspect the routing of the wire harness to make sure that the wire harness will not be pinched and damaged between the fuel rail and the cylinder head during installation.

    Install the 6 bolts and the LH fuel rail assembly.

    • Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and proceed inward.
    • To install, tighten to 10 Nm (89 lb-in).
    • Tighten an additional 45 degrees.

    GFD231463Courtesy of FORD MOTOR COMPANY
  114. NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.

    Using the crankshaft pulley bolt, turn the crankshaft until the fuel injection pump cam lobe is at BDC.

    GFD231464Courtesy of FORD MOTOR COMPANY
  115. NOTE: Valve cover is removed for clarity.
    NOTE: Apply clean engine oil to the fuel injection pump mounting pedestal bore.

    Install the fuel injection pump roller tappet.

    GFD231208Courtesy of FORD MOTOR COMPANY
  116. NOTE: Apply clean engine oil to the fuel injection pump mounting plate seal.

    Inspect the fuel injection pump mounting plate-to-valve cover gasket and replace if necessary.

    GFD231465Courtesy of FORD MOTOR COMPANY
  117. NOTE: Apply clean engine oil to the fuel injection pump mounting plate O-ring seals.

    Inspect the 2 fuel injection pump mounting plate O-ring seals and replace if necessary.

    GFD231466Courtesy of FORD MOTOR COMPANY
  118. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.

    Install the fuel injection pump on the fuel injection pump mounting plate.

    GFD231467Courtesy of FORD MOTOR COMPANY
  119. NOTE: Clean the fuel injection pump bolts and apply Thread Sealant with PTFE to the bolts.

    Install the fuel injection pump and the 2 bolts finger-tight.

    • Tighten to 10 Nm (89 lb-in).
    • Tighten an additional 45 degrees.

    GFD231206Courtesy of FORD MOTOR COMPANY
  120. NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.

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

    • Stage 1: Tighten to 32 Nm (24 lb-ft).
    • Stage 2: Wait 10 minutes to minimize pre-stress.
    • Stage 3: Tighten to 32 Nm (24 lb-ft).

    GFD231205Courtesy of FORD MOTOR COMPANY
  121. Install the high-pressure fuel tube bracket nut.

    • Tighten to 8 Nm (71 lb-in).

    GFD231204Courtesy of FORD MOTOR COMPANY
  122. Install the RH cylinder block drain plug or, if equipped, the block heater.

    • Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
    • Tighten the block heater to 40 Nm (30 lb-ft).

    GFD231332Courtesy of FORD MOTOR COMPANY
  123. Install the LH cylinder block drain plug.

    • Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.

    GFD231331Courtesy of FORD MOTOR COMPANY
  124. Attach the wiring harness retainer to the rear of the LH cylinder head.
    GFD231330Courtesy of FORD MOTOR COMPANY
  125. Install the cover and the pin-type retainer.
    GFD231329Courtesy of FORD MOTOR COMPANY
  126. Install the turbocharger coolant tube assembly and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231328Courtesy of FORD MOTOR COMPANY
  127. Install the RH engine lifting eye and the 2 bolts.

    • Tighten to 24 Nm (18 lb-ft).

    GFD231327Courtesy of FORD MOTOR COMPANY
  128. Install 8 new RH exhaust manifold studs.

    • Tighten to 12 Nm (106 lb-in).

    GFD231326Courtesy of FORD MOTOR COMPANY
  129. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Install a new gasket, RH exhaust manifold and 8 new nuts. Tighten in 2 stages in the sequence shown:

    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Stage 2: Tighten to 20 Nm (177 lb-in).

    GFD231468Courtesy of FORD MOTOR COMPANY
  130. Install the new oil supply tube filter, washer and bolt.

    1. Install a new oil supply tube filter in the oil supply tube block.
    2. Slide the new washer onto the oil supply tube block.
    3. Install the new banjo bolt into the oil supply tube block.

    GFD231469Courtesy of FORD MOTOR COMPANY
  131. Install the RH turbocharger oil supply tube.

    • Stage 1: Tighten to 18 Nm (159 lb-in).
    • Stage 2: Tighten 90 degrees.

    GFD231324Courtesy of FORD MOTOR COMPANY
  132. Install a new gasket, the turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.

    • Tighten to 45 Nm (33 lb-ft).

    GFD231323Courtesy of FORD MOTOR COMPANY
  133. Using 2 new sealing washers, install the 2 RH turbocharger coolant tubes and the new banjo bolts.

    • Stage 1: Tighten to 12 Nm (106 lb-in).
    • Stage 2: Tighten 60 degrees.

    GFD231322Courtesy of FORD MOTOR COMPANY
  134. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

    Install the RH oil supply tube into the quick connect fitting.

    GFD231470Courtesy of FORD MOTOR COMPANY
  135. Install the RH oil supply tube secondary latch.
    GFD231320Courtesy of FORD MOTOR COMPANY
  136. NOTE: Lubricate the cylinder block bore with clean engine oil.

    Using 2 new O-ring seals, install the RH turbocharger oil return tube in the cylinder block.

    GFD231319Courtesy of FORD MOTOR COMPANY
  137. Install a new gasket and the RH turbocharger oil return tube and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD231318Courtesy of FORD MOTOR COMPANY
  138. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

    Connect the turbocharger wastegate regulating valve hose to the RH turbocharger assembly.

    GFD231317Courtesy of FORD MOTOR COMPANY
  139. NOTE: Make sure the heat shield does not contact the wastegate arm.

    Install the 2 upper RH exhaust manifold heat shield and the 5 bolts.

    • Tighten to 12 Nm (106 lb-in).

    GFD231316Courtesy of FORD MOTOR COMPANY
  140. Install the Crankshaft Position (CKP) sensor and install the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231315Courtesy of FORD MOTOR COMPANY
  141. Connect the CKP sensor electrical connector.
    GFD231314Courtesy of FORD MOTOR COMPANY
  142. Install the wiring harness grommet.
    GFD231313Courtesy of FORD MOTOR COMPANY
  143. Install the wiring harness retainer stud bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231312Courtesy of FORD MOTOR COMPANY
  144. Install the heat shield and the nut.

    • Tighten to 10 Nm (89 lb-in).

    GFD231311Courtesy of FORD MOTOR COMPANY
  145. Install the LH turbocharger coolant tube bracket-to-cylinder head nut.

    • Tighten to 10 Nm (89 lb-in).

    GFD231310Courtesy of FORD MOTOR COMPANY
  146. Install 8 new LH exhaust manifold studs.

    • Tighten to 12 Nm (106 lb-in).

    GFD231309Courtesy of FORD MOTOR COMPANY
  147. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Install a new gasket, LH exhaust manifold and turbocharger assembly and 8 new nuts. Tighten the nuts in 2 stages in the sequence shown:

    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Stage 2: Tighten to 20 Nm (177 lb-in).

    GFD231471Courtesy of FORD MOTOR COMPANY
  148. Install a new gasket the LH turbocharger and the 3 new exhaust manifold-to-turbocharger bolts.

    • Tighten to 45 Nm (33 lb-ft).

    GFD231307Courtesy of FORD MOTOR COMPANY
  149. Install the new oil supply tube filter, washer and bolt.

    1. Install a new oil supply tube filter in the oil supply tube block.
    2. Slide the new washer onto the oil supply tube block.
    3. Install the new bolt into the oil supply tube block.

    GFD231472Courtesy of FORD MOTOR COMPANY
  150. Install the LH turbocharger oil supply tube.

    • Stage 1: Tighten to 18 Nm (159 lb-in).
    • Stage 2: Tighten 90 degrees.

    GFD231306Courtesy of FORD MOTOR COMPANY
  151. Using 2 new sealing washers, install the 2 LH turbocharger coolant tubes and the new banjo bolts.

    • Stage 1: Tighten to 12 Nm (106 lb-in).
    • Stage 2: Tighten 60 degrees.

    GFD231305Courtesy of FORD MOTOR COMPANY
  152. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

    Install the LH oil supply tube into the quick connect fitting.

    GFD231473Courtesy of FORD MOTOR COMPANY
  153. Install the LH oil supply tube secondary latch.
    GFD231303Courtesy of FORD MOTOR COMPANY
  154. NOTE: Lubricate the oil pan bore with clean engine oil.

    Using 2 new O-ring seals, install the LH turbocharger oil return tube in the oil pan.

    GFD231302Courtesy of FORD MOTOR COMPANY
  155. Install a new gasket, turbocharger oil return tube and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD231301Courtesy of FORD MOTOR COMPANY
  156. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

    Connect the turbocharger wastegate regulating valve hose to the LH turbocharger assembly.

    GFD231300Courtesy of FORD MOTOR COMPANY
  157. Install LH Camshaft Position (CMP) sensor and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231299Courtesy of FORD MOTOR COMPANY
  158. Connect the LH CMP sensor electrical connector.
    GFD231298Courtesy of FORD MOTOR COMPANY
  159. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
    GFD231297Courtesy of FORD MOTOR COMPANY
  160. Install the RH CMP sensor and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231474Courtesy of FORD MOTOR COMPANY
  161. Connect the RH CMP sensor electrical connector.
    GFD231295Courtesy of FORD MOTOR COMPANY
  162. Connect the RH VCT solenoid and the 3 RH ignition coil-on-plug electrical connectors.

    • Attach all of the wiring harness retainers.

    GFD231203Courtesy of FORD MOTOR COMPANY
  163. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    NOTE: Make sure the fuel rail wiring harnesses are routed correct.
    NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.

    Using new intake manifold, coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts. Tighten in the sequence shown in 2 stages.

    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

    GFD231475Courtesy of FORD MOTOR COMPANY
  164. Connect the 2 turbocharger coolant hoses to the intake manifold.
    GFD231201Courtesy of FORD MOTOR COMPANY
  165. Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD231200Courtesy of FORD MOTOR COMPANY
  166. Attach the 2 wire harness-to-intake manifold retainers.
    GFD231199Courtesy of FORD MOTOR COMPANY
  167. Connect the turbocharger wastegate regulating valve electrical connector.
    GFD231198Courtesy of FORD MOTOR COMPANY
  168. Connect the Manifold Absolute Pressure (MAP) /Intake Air Temperature 2 (IAT2) sensor electrical connector.
    GFD231197Courtesy of FORD MOTOR COMPANY
  169. Connect and attach the 2 fuel injector wiring harness electrical connectors.
    GFD231196Courtesy of FORD MOTOR COMPANY
  170. Connect the KS sensor electrical connector.
    GFD231294Courtesy of FORD MOTOR COMPANY
  171. Install the oil level indicator.
    GFD231195Courtesy of FORD MOTOR COMPANY
  172. Attach all the wiring harness retainers to the LH valve cover and stud bolts.
  173. Connect the 3 LH ignition coil-on-plug electrical connectors.
    GFD231191Courtesy of FORD MOTOR COMPANY
  174. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.

    Install the EOP switch.

    • To install, tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.

    GFD231293Courtesy of FORD MOTOR COMPANY
  175. Using a new gasket, install the oil filter adapter and the 3 bolts.

    • Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.

    GFD231292Courtesy of FORD MOTOR COMPANY
  176. Connect the EOP electrical connector.

    • Attach the EOP wiring harness retainer to the engine block.

    GFD231291Courtesy of FORD MOTOR COMPANY
  177. Install the stud, generator and the nut and bolt.

    • Tighten the stud to 8 Nm (71 lb-in).

    • Tighten the nut and bolt to 47 Nm (35 lb-ft).

    GFD231288Courtesy of FORD MOTOR COMPANY
  178. Connect the LH camshaft VCT solenoid electrical connector.
    GFD231189Courtesy of FORD MOTOR COMPANY
  179. Connect the Throttle Position (TP) sensor and electronic Throttle Body (TB) electrical connectors.
    GFD231188Courtesy of FORD MOTOR COMPANY
  180. Connect the electrical connector and install the noise insulator shield for the fuel injection pump.
    GFD231187Courtesy of FORD MOTOR COMPANY
  181. Install the PCV tube and connect the 2 quick connect couplings. For additional information, refer to Fuel System General Information .
    GFD231178Courtesy of FORD MOTOR COMPANY
  182. Install the lower radiator hose to the thermostat housing.
    GFD231192Courtesy of FORD MOTOR COMPANY
  183. NOTE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Install the RH Charge Air Cooler (CAC) tube and turbocharger intake tube as an assembly and install the RH CAC tube nut to the intake manifold.

    • Tighten to 6 Nm (53 lb-in).

    GFD231186Courtesy of FORD MOTOR COMPANY
  184. NOTE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Install the RH turbocharger intake tube nut.

    • Tighten to 6 Nm (53 lb-in).

    GFD231185Courtesy of FORD MOTOR COMPANY
  185. NOTE: Align the index marks for the RH turbocharger intake pipe.

    Install the RH turbocharger intake pipe to the RH turbocharger and tighten the clamp.

    • Tighten to 5 Nm (44 lb-in).

    GFD231184Courtesy of FORD MOTOR COMPANY
  186. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube to the RH turbocharger and tighten the clamp.

    • Tighten to 5 Nm (44 lb-in).

    GFD231183Courtesy of FORD MOTOR COMPANY
  187. Connect the RH turbocharger bypass valve electrical connector.
    GFD231182Courtesy of FORD MOTOR COMPANY
  188. NOTE: Align the index marks for the LH turbocharger intake tube.

    Install the LH turbocharger intake tube to the LH turbocharger and tighten the clamp.

    • Tighten to 5 Nm (44 lb-in).

    GFD231181Courtesy of FORD MOTOR COMPANY
  189. Install the turbocharger wastegate regulating valve hoses to the turbocharger wastegate regulating valve and to the RH CAC tube.
    GFD231180Courtesy of FORD MOTOR COMPANY
  190. Connect the LH turbocharger bypass valve electrical connector.
    GFD231179Courtesy of FORD MOTOR COMPANY
  191. Install the accessory drive belt tensioner and the 3 bolts.

    • Tighten to 11 Nm (97 lb-in).

    GFD231215Courtesy of FORD MOTOR COMPANY
  192. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
    GFD231214Courtesy of FORD MOTOR COMPANY
  193. Using a new O-ring seal and gasket seal, connect the A/C tube to the compressor and install the nut.

    • Tighten to 15 Nm (133 lb-in).

    GFD231177Courtesy of FORD MOTOR COMPANY
  194. If equipped, connect the block heater electrical connector and install the heat shield.
    GFD231286Courtesy of FORD MOTOR COMPANY
  195. Install the Engine Lift Eye on the LH cylinder head.
    GFD231260Courtesy of FORD MOTOR COMPANY
  196. Using the Floor Crane and Spreader Bar, remove the engine from the stand.
    GFD231261Courtesy of FORD MOTOR COMPANY
  197. Install the crankshaft sensor ring.
    GFD231285Courtesy of FORD MOTOR COMPANY
  198. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.

    Install the flexplate and the 8 bolts.

    • Tighten in the sequence shown to 80 Nm (59 lb-ft).

GFD231476Courtesy of FORD MOTOR COMPANY
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