Engine Mechanical: Mechanical: Engine: Assembly: Engine

Special Tools

Illustration	Tool Name	Tool Number
	Service Set, Camshaft	303-017 (T65L-6250-A)
	Installer, Crankshaft Front Oil Seal	303-335 (T82L-6316-A)
	Installer, Crankshaft Front Oil Seal	303-474 (T94P-6701-AH)
	Installer, Crankshaft Vibration Damper	303-175 (T82L-6316-A)
	Replacer, Rear Crankshaft Seal	303-516 (T95P-6701-BH)
	Spacer, Rear Crank Seal Replacer	303-561 (T96T-6701-B)
	Adapter, Crankshaft Rear Seal (Use only the adapter retaining bolts)	303-518 (T95P-6701-DH)
	Adapter, Crankshaft Rear Seal (Use only the adapter and the center jack screw)	303-S560 (T96T-6701-A)
	Engine Lifting Brackets	303-D095 (D94L-6001-A)
	Synchronizer Alignment Gauge	303-630

Material

Item	Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent	WSS-M2C930-A
Motorcraft Metal Surface Cleaner ZC-21	WSE-M5B392-A
Silicone Gasket and Sealant TA 30	WSE-M4G323-A4
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A
Thread Sealant with PTFE TA-24	WSK-M2G350-A2

Fig 1: Exploded View Of Engine - Lower Components

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6255	Camshaft synchronizer drive gear
2	6268	Timing chain
3	6A303	Engine balance shaft drive gear
4	6A304	Engine balance shaft driven gear
5	6C341	Balance shaft thrust plate
6	6A311	Engine dynamic balance shaft
7	W705934	Woodruff key
8	6261	Camshaft bearing
9	6A333	Balance shaft bearing (2 required)
10	6010	Cylinder block
11	6K564	Tappet guide plate and retainer
12	6500	Valve tappet
13	376958	Balance shaft cover plug
14	6337	Crankshaft thrust main bearing
15	6701	Crankshaft rear oil seal
16	6A338	Crankshaft main bearing (lower)
17	6A339	Crankshaft thrust main bearing
18	6325	Rear main bearing cap
19	6327	Main bearing cap
20	6687	Oil pan baffle
21	6622	Oil pump screen cover and tube
22	6675	Oil pan
23	6625	Oil pump inlet tube gasket
24	6334	Main bearing cap
25	6329	Main bearing cap
26	6303	Crankshaft
27	388907	Woodruff key
28	6333	Crankshaft main bearing (upper)
29	6284	Timing chain vibration damper
30	6263	Camshaft rear bearing
31	6262	Camshaft center bearing
32	6250	Camshaft
33	6265	Camshaft gear spacer
34	6269	Camshaft thrust plate
35	6256	Camshaft gear
36	6303	Crankshaft gear
37	6148	Piston rings
38	6135	Piston pin
39	6200	Connecting rod
40	6211	Connecting rod bearing
41	6210	Connecting rod cap
42	6200	Connecting rod assembly
43	6100	Piston and connecting rod assembly
44	6108	Piston

Fig 2: Exploded View Of Engine - Upper Components

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	9424	Upper intake manifold assembly
2	9Y456	Exhaust gas recirculation (EGR) system module
3	9F715	Idle speed control valve assembly
4	9E926	Throttle body assembly
5	9F797	Fuel supply manifold assembly
6	9E498	Engine vacuum tube harness assembly
7	9J447	Lower intake manifold assembly
8	8594	Thermostat housing
9	8575	Thermostat
10	8255	Coolant outlet gasket
11	18663	Coolant pump outlet tube
12	-	Coolant inlet hose (part of 18663)
13	-	Coolant outlet hose (part of 18663)
14	8548	Coolant bypass tube assembly
15	9439	Lower intake manifold gasket, RH
16	9439	Lower intake manifold gasket, LH
17	9A424	Lower intake manifold gasket seal (2 required)
18	6766	Oil fill cap
19	6754	Oil level indicator tube
20	12405	Spark plug (6 required)
21	6B209	Drive belt tensioner
22	3C631	Power steering pump bracket

Fig 3: Exploded View Of Engine - Front Components

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6B288	Camshaft position (CMP) sensor
2	8507	Coolant pump housing gasket
3	12A362	Camshaft synchronizer
4	6A618	Oil pump intermediate shaft
5	6020	Engine front cover gasket
6	6010	Cylinder block
7	6019	Engine front cover
8	-	Oil cooler seal (part of 6A642)
9	6A642	Oil cooler and tube assembly
10	-	Oil cooler mounting bolt (part of 6A642)
11	6714	Oil bypass filter
12	6C315	Crankshaft position (CKP) sensor
13	8501	Coolant pump
14	6B321	Crankshaft damper and pulley assembly
15	6K375	Flywheel

Fig 4: Exploded View Of Cylinder Heads

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6565	Push rod (12 required)
2	6564	Rocker arm (12 required)
3	6A528	Rocker arm pivot (12 required)
4	N808305	Rocker arm bolt
5	6A505	Valve cover, LH
6	6518	Valve spring key (24 required)
7	6514	Valve spring retainer (12 required)
8	6513	Valve spring (12 required)
9	6A517	Valve seal/seat (12 required)
10	6049	Cylinder head, LH
11	6507	Exhaust valve
12	6505	Intake valve
13	6083	Cylinder head gasket, LH
14	376958	Camshaft rear bearing cover
15	6A335	Balance shaft cover plug
16	6010	Cylinder block
17	87744	Engine block plug
18	9278	Oil pressure sender switch
19	6C057	Engine block plug
20	6051	Cylinder head gasket, RH
21	6050	Cylinder head, RH
22	6582	Valve cover, RH
23	6K564	Tappet guide plate and retainer
24	6500	Valve tappet

Fig 5: Exploded View Of Engine - External Components

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	12280	Spark plug wire set, RH
2	12281	Spark plug wire set, LH
3	6C342	Crankcase vent hose
4	12029	Ignition coil
5	9D477	EGR system module-to-exhaust manifold tube
6	N806991	EGR system module-to-exhaust manifold tube connector
7	9431	Exhaust manifold, LH
8	9448	Exhaust manifold gasket (2 required)
9	9430	Exhaust manifold, RH
10	9N454	Heat shield

CAUTION: 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, can cause engine failure.

CAUTION: The moving components must be lubricated with clean engine oil before assembly.

CAUTION: The components with oil holes must be correctly aligned with the oil feed holes.

1. If necessary, install the following:
   1. Cylinder block dowels
   2. Oil gallery plugs
   3. Coolant jacket plugs
Fig 6: Identifying Cylinder Block Dowels, Oil Gallery Plugs And Coolant Jacket Plugs
Courtesy of FORD MOTOR CO.
2. Using the Camshaft Service Set, install the 2 engine dynamic balance shaft bearings.
Fig 7: Identifying Engine Dynamic Balance Shaft Bearings
Courtesy of FORD MOTOR CO.
3. Using the Camshaft Service Set, install the 4 camshaft bearings.
Fig 8: Identifying Camshaft Bearings
Courtesy of FORD MOTOR CO.
4. Install the following:
   1. Engine dynamic balance shaft bearing cover
   2. Camshaft bearing cover
Fig 9: Identifying Engine Dynamic Balance Shaft Bearing Cover & Camshaft Bearing Cover
Courtesy of FORD MOTOR CO.
5. If equipped, install the block heater.
   • Tighten to 2 Nm (18 lb-in).
Fig 10: Locating Block Heater
Courtesy of FORD MOTOR CO.
CAUTION: Make sure the components are installed in the correct locations.
NOTE: Lubricate the crankshaft main bearings with clean engine oil prior to installation.
6. Install the 4 crankshaft upper main bearings and the crankshaft upper thrust main bearing.
Fig 11: Identifying Crankshaft Upper Main Bearings & Upper Thrust Main Bearing
Courtesy of FORD MOTOR CO.
CAUTION: The crankshaft journals must be protected from damage when installing the crankshaft.
7. Position the crankshaft.
Fig 12: Locating Crankshaft
Courtesy of FORD MOTOR CO.
CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
NOTE: If the rear main bearing cap is not installed within 4 minutes, remove the sealant and reapply.
8. Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket and sealant to the rear main bearing cap-to-cylinder block parting line.
Fig 13: Applying Silicone Gasket And Sealant To Rear Main Bearing Cap-To-Cylinder Block Parting Line
Courtesy of FORD MOTOR CO.
9. Install the main bearing caps. Tighten the bolts in 2 stages.
   • Stage 1: Tighten to 55 N.m (41 lb-ft).
   • Stage 2: Rotate an additional 90 degrees.
Fig 14: Locating Main Bearing Caps
Courtesy of FORD MOTOR CO.
10. Using a piston ring compressor, compress the piston rings.
Fig 15: Compressing Piston Rings
Courtesy of FORD MOTOR CO.
CAUTION: Inspect the piston clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
CAUTION: Do not damage the cylinder wall with the sharp edges of the connecting rod.
NOTE: 4.2L shown, 3.9L similar.
11. Install the piston with the arrow on the piston face pointing toward the front of the engine.
Fig 16: Installing Piston
Courtesy of FORD MOTOR CO.
CAUTION: Inspect the connecting rod bearing clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
CAUTION: The connecting rod cap will fit only one way.
12. Position the lower connecting rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal.
Fig 17: Positioning Lower Connecting Rod Bearing And Connecting Rod Cap
Courtesy of FORD MOTOR CO.
13. Tighten the 2 connecting rod cap bolts in 3 stages.
    • Stage 1: Tighten to 25 N.m (18 lb-ft).
    • Stage 2: Tighten to 45 N.m (33 lb-ft).
    • Stage 3: Tighten an additional 105 degrees.
Fig 18: Tightening Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
14. Install the remaining pistons and the connecting rods.
15. Install the oil pan baffle and the 5 retaining nuts.
    • Tighten to 32 Nm (24 lb-ft).
Fig 19: Locating Oil Pan Baffle Nuts
Courtesy of FORD MOTOR CO.
16. Using a new gasket, install the oil pump screen cover and tube.
    1. Tighten to 25 Nm (18 lb-ft).
    2. Tighten to 32 Nm (24 lb-ft).
Fig 20: Installing Oil Pump Screen Cover And Tube
Courtesy of FORD MOTOR CO.
CAUTION: Do not damage the camshaft lobes when installing the camshaft.
17. Install the camshaft, camshaft spacer and camshaft key.
Fig 21: Locating Camshaft, Camshaft Spacer And Camshaft Key
Courtesy of FORD MOTOR CO.
18. Install the camshaft thrust plate and 2 bolts.
    • Tighten to 11 Nm (8 lb-ft).
Fig 22: Locating Camshaft Thrust Plate Bolts
Courtesy of FORD MOTOR CO.
19. Install the engine dynamic balance shaft assembly and 2 bolts.
    • Tighten to 11 Nm (8 lb-ft).
Fig 23: Balance Shaft Driven Gear, Thrust Plate & Bolts
Courtesy of FORD MOTOR CO.
NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and the camshaft keyway will be at 6 o'clock on the camshaft.
20. Install the engine balance shaft drive gear so that the timing mark lines up with the timing mark on the engine balance shaft driven gear.
Fig 24: Installing Engine Balance Shaft Drive Gear
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the valve tappets with clean engine oil prior to installing. If reusing the valve tappets, make sure to install them in their original locations.
21. Install the 12 valve tappets.
    • Install the valve tappets.
    • Install the tappet guide plates and retainers.
    • Install the bolts and tighten to 12 Nm (9 lb-ft).
Fig 25: Locating Valve Tappet Guide Plate & Retainer Bolt
Courtesy of FORD MOTOR CO.
22. Install the timing chain tensioner and bolts.
    • Position the timing chain tensioner.
    • Install the bolts and tighten to 11 Nm (8 lb-ft).
Fig 26: Locating Timing Chain Tensioner Bolts
Courtesy of FORD MOTOR CO.
23. If necessary, compress the tensioner pad and install a retaining pin.
Fig 27: Compressing Tensioner Pad And Installing Retaining Pin
Courtesy of FORD MOTOR CO.
24. Rotate the crankshaft so the No. 1 piston is at top dead center (TDC) and the keyway is at the 12 o'clock position.
Fig 28: Locating Crankshaft Keyway At 12 O'Clock Position
Courtesy of FORD MOTOR CO.
25. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
Fig 29: Locating Camshaft Sprocket Timing Mark
Courtesy of FORD MOTOR CO.
26. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
Fig 30: Identifying Timing Chain & Sprockets
Courtesy of FORD MOTOR CO.
CAUTION: All timing marks must be aligned with the No. 1 cylinder set on TDC of the compression stroke or the synchronizer assembly will not be installed correctly.
NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.
27. Make sure the timing marks and the keyways are aligned.
Fig 31: Aligning Crankshaft Timing Marks & Keyways
Courtesy of FORD MOTOR CO.
28. Remove the retaining pin.
Fig 32: Locating Retaining Pin
Courtesy of FORD MOTOR CO.
29. Install the synchronizer drive gear and the bolt.
    • Tighten to 45 Nm (33 lb-ft).
Fig 33: Locating Camshaft Synchronizer Drive Gear Bolt
Courtesy of FORD MOTOR CO.
NOTE: Use Thread Sealant with PTFE on studs No. 4 and 6 and bolt No. 12.
30. Install the engine front cover studs in their original locations.
    • Tighten the 4 engine front cover studs to 7 Nm (62 lb-in).
CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
NOTE: Clean and inspect the mating surfaces.
31. Using a new gasket, install the engine front cover.
    • Using a new gasket, install the coolant pump.
    • Tighten the fasteners in the sequence shown.
      • Tighten capscrew No. 12 to 10 Nm (89 lb-in).
      • Tighten all other fasteners to 28 Nm (21 lb-ft).
Fig 34: Identifying Front Cover Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new crankshaft front seal lips with clean engine oil prior to installation.
32. Assemble the special tools, then place the crankshaft front seal onto the special tools.
Fig 35: Identifying Special Tools (303--335) And (303--474)
Courtesy of FORD MOTOR CO.
33. Using the special tools, install the crankshaft front seal.
Fig 36: Installing Crankshaft Front Seal Using Special Tools (303--335) And (303--474)
Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
34. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Fig 37: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
Courtesy of FORD MOTOR CO.
35. Lubricate the crankshaft pulley sealing surface with clean engine oil.
Fig 38: Lubricating Crankshaft Pulley Sealing Area With Clean Engine Oil
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the crankshaft front seal inner lip with clean engine oil prior to installation.
36. Using the special tool, install the crankshaft pulley.
Fig 39: Installing Crankshaft Pulley Using Special Tool (303--175)
Courtesy of FORD MOTOR CO.
37. Install the crankshaft pulley washer and the bolt.
    • Tighten to 160 Nm (118 lb-ft).
Fig 40: Locating Crankshaft Pulley Washer Bolt
Courtesy of FORD MOTOR CO.
CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center TDC of the compression stroke on the No. 1 cylinder.
CAUTION: A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.
38. Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
Fig 41: Installing Special Tool On Camshaft Synchronizer
Courtesy of FORD MOTOR CO.
NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.
NOTE: During installation, the arrow on the special tool will rotate clockwise as the gears engage.
39. Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 54 degrees from the centerline of the engine.
Fig 42: Installing Camshaft Synchronizer Housing Assembly So Arrow On Synchronizer Alignment Tool Is 54 Degrees From Centerline Of The Engine
Courtesy of FORD MOTOR CO.
40. Install the camshaft synchronizer retaining bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 43: Locating Camshaft Synchronizer Retaining Bolt
Courtesy of FORD MOTOR CO.
41. Install the CMP sensor and the 2 bolts.
    • Tighten to 3 Nm (27 lb-in).
Fig 44: Locating CMP Sensor Bolts
Courtesy of FORD MOTOR CO.
NOTE: If the oil pan is not installed within 4 minutes, remove the sealant and reapply.
42. Clean and apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.
    1. Apply silicone gasket and sealant to the rear main bearing cap.
    2. Install the oil pan rear seal.
    3. Clean the oil pan mating surfaces with metal surface cleaner and apply silicone gasket and sealant to the oil pan mating surfaces.
Fig 45: Applying Silicone Gasket And Sealant To Oil Pan Sealing Areas Shown And Installing Oil Pan Rear Seal
Courtesy of FORD MOTOR CO.
43. Install the oil pan and 17 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 46: Identifying Oil Pan Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
44. Install the oil pressure sender.
    • Tighten to 27 Nm (20 lb-ft).
Fig 47: Locating Oil Pressure Sensor
Courtesy of FORD MOTOR CO.
CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
45. If equipped, install a new oil cooler and tube assembly and bolt.
    • Tighten to 35 Nm (26 lb-ft).
Fig 48: Locating Oil Cooler And Tube Assembly And Bolt
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new engine oil filter seal with clean engine oil prior to installation.
46. Install a new engine oil filter.
    • Tighten one half turn after the gasket makes contact with the oil filter housing.
Fig 49: Engine Oil Filter
Courtesy of FORD MOTOR CO.
NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.
47. Using new gaskets, install the RH and the LH cylinder heads.
Fig 50: Cylinder Head & Gasket
Courtesy of FORD MOTOR CO.
CAUTION: Always use new bolts.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
48. Install the new bolts. Make sure the bolts are installed in the correct locations.
    1. Install the new long bolts.
    2. Install the new short bolts.
Fig 51: Identifying Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
49. Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 40 Nm (30 lb-ft).
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
Fig 52: Identifying Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
CAUTION: Each bolt must be loosened and the final tightening carried out prior to working on the next bolt in the sequence. Do not loosen all of the bolts at one time.
50. Carry out the following final tightening process on each bolt in the sequence shown.
    • Long bolts:
      • Loosen and back out 3 turns.
      • Tighten to 45 Nm (33 lb-ft).
      • Tighten an additional 180 degrees.
      • Continue on to the next bolt in sequence.
    • Short bolts:
      • Loosen and back out 3 turns.
      • Tighten to 25 Nm (18 lb-ft).
      • Tighten an additional 180 degrees.
      • Continue on to the next bolt in sequence.
Fig 53: Identifying Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
51. Install the 3 lower exhaust manifold studs on both cylinder heads.
    • Tighten to 8 Nm (71 lb-in).
Fig 54: Lower Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the push rods with clean engine oil prior to installation. If reusing the push rods, make sure to install them in their original locations.
52. Install the 12 push rods.
Fig 55: Pushrods
Courtesy of FORD MOTOR CO.
NOTE: If reusing the rocker arms, make sure to install them in their original locations.
53. Install the 12 rocker arms.
    • Position the rocker arms and pivots.
    • Hand-start the 12 bolts.
    • Tighten the 12 bolts in 2 stages.
      • Stage 1: Tighten to 5 Nm (44 lb-in).
      • Stage 2: Tighten to 32 Nm (24 lb-ft).
Fig 56: Bolts, Rocker Arm Pivots & Rocker Arms
Courtesy of FORD MOTOR CO.
NOTE: Install new gaskets in the valve covers.
NOTE: RH shown, LH similar.
54. Install the valve covers.
    1. Position the valve covers.
    2. Install the bolts and tighten to 10 Nm (89 lb-in).
    3. Install the stud bolts and tighten to 10 Nm (89 lb-in).
Fig 57: Identifying Valve Cover
Courtesy of FORD MOTOR CO.
55. Using a new gasket, install the RH exhaust manifold. Loosely install the 6 RH nuts.
56. Tighten the 6 nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
Fig 58: Identifying Exhaust Manifold Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.
57. Install the heat shield and the 3 nuts.
    • Tighten to 10 Nm (89 lb-in).
Fig 59: Locating Heat Shield Nuts
Courtesy of FORD MOTOR CO.
58. Using a new gasket, install the LH exhaust manifold. Loosely install the 6 nuts.
Fig 60: Locating LH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
59. Tighten the nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
Fig 61: Identifying Exhaust Manifold Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.
60. Refer to the illustration for intake manifold sealing components.

    Item	Part Number	Description
    1	9439	RH intake manifold gasket
    2	9439	LH intake manifold gasket
    3	9A424	Intake manifold rear end seal (part of 9439)
    4	9A425	Intake manifold front end seal (part of 9439)

Fig 62: Lower Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.
61. Install the lower intake manifold front and rear end seals.
    1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated.
    2. Install the lower intake manifold front and rear end seals.
Fig 63: Identifying Lower Intake Manifold Front & Rear Seals
Courtesy of FORD MOTOR CO.
62. Position the intake manifold gaskets.
Fig 64: Identifying Manifold Gaskets
Courtesy of FORD MOTOR CO.
NOTE: The lower intake manifold must be installed within 4 minutes of applying the sealant.
63. Position the lower intake manifold.
    1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points indicated.
    2. Position the lower intake manifold.
Fig 65: Identifying Lower Intake Manifold
Courtesy of FORD MOTOR CO.
NOTE: Make sure the bolts are installed in the correct locations.
64. Install the 6 long bolts.
Fig 66: Installing Long Bolts
Courtesy of FORD MOTOR CO.
65. Install the 8 short bolts.
Fig 67: Installing Short Bolts
Courtesy of FORD MOTOR CO.
66. Tighten the lower intake manifold bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 5 N.m (44 lb-in).
    • Stage 2: Tighten to 10 N.m (89 lb-in).
Fig 68: Identifying Lower Intake Manifold Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
67. Install new O-ring seals on the fuel injectors.
Fig 69: Fuel Injector O-Rings
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seals with clean engine oil to aid installation.
68. Install the fuel injectors and retaining clips on the fuel supply manifold.
Fig 70: Fuel Injectors & Clips
Courtesy of FORD MOTOR CO.
69. Install the fuel rail, fuel injectors and fuel charging harness as an assembly and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 71: Locating Fuel Rail, Fuel Injectors & Fuel Charging Harness
Courtesy of FORD MOTOR CO.
70. Using new gaskets, install the upper intake manifold and 8 bolts.
    • Tighten the 8 upper intake manifold bolts in 2 stages in the sequence shown.
      • Stage 1: Tighten to 6 Nm (53 lb-in).
      • Stage 2: Tighten to 10 Nm (89 lb-in).
Fig 72: Identifying Upper Intake Manifold Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
71. Position the engine harness onto the engine and connect the engine harness-to-fuel charging harness electrical connector.
Fig 73: Locating Engine Harness-To-Fuel Charging Harness Electrical Connector
Courtesy of FORD MOTOR CO.
72. Position the vacuum harness onto the engine and connect the vacuum harness connection.
Fig 74: Locating Vacuum Harness
Courtesy of FORD MOTOR CO.
73. Install the ignition coil and 3 bolts.
    • Tighten to 6 Nm (53 lb-in).
Fig 75: Locating Ignition Coil Bolts
Courtesy of FORD MOTOR CO.
74. Install the engine harness pin-type retainer and connect the ignition coil electrical connector.
Fig 76: Locating Ignition Coil Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: Do not tighten the EGR system module-to-manifold tube lower fitting.
75. Install the EGR system module-to-manifold tube.
Fig 77: Locating EGR System Module-To-Manifold Tube
Courtesy of FORD MOTOR CO.
76. Attach the wire retainer to the throttle position (TP) sensor stud bolt.
Fig 78: Locating Wire Retainer
Courtesy of FORD MOTOR CO.
77. Connect the following:
    1. Idle air control (IAC) electrical connector
    2. TP sensor electrical connector
    3. Exhaust gas recirculation (EGR) system module electrical connector
    4. EGR system module vacuum connector
    5. EGR system module-to-exhaust manifold tube upper fitting and tighten to 40 Nm (30 lb-ft)
Fig 79: Identifying EGR System Module Vacuum Connector & Throttle Position Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
78. Tighten the EGR system module-to-manifold tube lower fitting.
    • Tighten to 40 Nm (30 lb-ft).
Fig 80: EGR Tube At Exhaust Manifold
Courtesy of FORD MOTOR CO.
79. Connect the cylinder head temperature (CHT) sensor electrical connector.
Fig 81: Locating Cylinder Head Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
80. Connect the knock sensor (KS) electrical connector.
Fig 82: Locating Knock Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
81. Install the 4 engine harness pin-type retainers.
Fig 83: Locating Engine Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
NOTE: Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs and the ignition coil.
82. Install and connect the spark plug wires and retainers as an assembly.
Fig 84: Locating Spark Plug Wires & Retainers
Courtesy of FORD MOTOR CO.
NOTE: Install a new oil level indicator tube O-ring seal.
83. Install the oil level indicator tube and the retaining nut.
    • Tighten to 10 Nm (89 lb-in).
Fig 85: Oil Level Indicator Tube & Nut
Courtesy of FORD MOTOR CO.
84. Connect the quick disconnect crankcase vent hose to the intake manifold.
Fig 86: Locating Quick Connect Crankcase Vent Hose
Courtesy of FORD MOTOR CO.
85. Connect the quick disconnect crankcase vent hose and connect the crankcase vent hose valve electrical connector.
Fig 87: Locating Crankcase Vent Hose Valve Electrical Connector
Courtesy of FORD MOTOR CO.
86. Connect the intake manifold runner control (IMRC) electrical connector.
Fig 88: Locating Intake Manifold Runner Control Electrical Connector
Courtesy of FORD MOTOR CO.
87. Connect the CMP sensor electrical connector.
Fig 89: Locating CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
88. Connect the oil pressure sensor electrical connector and install the engine harness pin-type retainer.
Fig 90: Locating Oil Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
89. Install the RH engine mount bracket and 4 bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 91: Locating RH Engine Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
90. Install the catalyst monitor sensor electrical connector bracket.
    • Tighten to 28 Nm (21 lb-ft).
Fig 92: Locating Catalyst Monitor Sensor Electrical Connector Bracket Nut
Courtesy of FORD MOTOR CO.
91. Connect the CKP sensor electrical connectors.
Fig 93: Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
92. Install the power steering pump bracket and 4 mounting bolts.
    1. Tighten to 25 Nm (18 lb-ft).
    2. Tighten to 48 Nm (35 lb-ft).
Fig 94: Identifying Power Steering Pump Bracket & Mounting Bolts
Courtesy of FORD MOTOR CO.
93. Install the accessory drive belt tensioner and 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 95: Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
NOTE: Install a new coolant pump outlet tube O-ring seal and lubricate with clean engine coolant.
94. Install the coolant pump outlet tube.
    • Install the 2 bolts and tighten to 10 Nm (89 lb-in).
    • Connect the 3 coolant hoses.
      • Reposition the clamps.
Fig 96: Locating Coolant Pump Outlet Tube Bolts
Courtesy of FORD MOTOR CO.
95. Install the A/C compressor bracket and 4 bolts.
    • Tighten to 47 Nm (35 lb-ft).
Fig 97: Locating A/C Compressor Bracket Bolts
Courtesy of FORD MOTOR CO.
96. Install the A/C compressor mounting bracket brace and generator mounting bracket as an assembly and install the 4 bolts.
    1. Tighten to 25 Nm (18 lb-ft).
    2. Tighten to 47 Nm (35 lb-ft).
Fig 98: Installing A/C Compressor Mounting Bracket Brace And Generator Mounting Bracket
Courtesy of FORD MOTOR CO.
97. Install the coolant extension tube and bracket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 99: Locating Coolant Pump Extension Tube & Bracket Bolt
Courtesy of FORD MOTOR CO.
98. Install the generator and 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 100: Locating Generator Bolts
Courtesy of FORD MOTOR CO.
99. Connect the generator.
    • Install the B+ wire terminal and nut and tighten to 8 Nm (71 lb-in).
    • Connect the generator electrical connector.
Fig 101: Locating Generator Electrical Connector
Courtesy of FORD MOTOR CO.
100. Install the accessory drive idler pulley and bolt.
     • Tighten to 47 Nm (35 lb-ft).
Fig 102: Locating Accessory Drive Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
101. Install the coolant pump pulley and 4 bolts.
     • Tighten to 11 Nm (8 lb-ft).
Fig 103: Identifying Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
102. Install the special tools.
Fig 104: Identifying Special Tool (303--D095)
Courtesy of FORD MOTOR CO.
103. Install the engine lifting equipment.
Fig 105: Engine Lifting Equipment
Courtesy of FORD MOTOR CO.
104. Remove the engine from the stand.
NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.
105. Assemble the special tools and the crankshaft rear seal.
Fig 106: Identifying Special Tools And Crankshaft Rear Seal
Courtesy of FORD MOTOR CO.
106. Install the special tools on the rear of the crankshaft.
Fig 107: Installing Special Tools On Rear Of Crankshaft
Courtesy of FORD MOTOR CO.
107. Install the crankshaft rear seal. Tighten the center jack screw until the spacer contacts the engine block.
Fig 108: Installing Crankshaft Rear Seal
Courtesy of FORD MOTOR CO.
108. Install the flywheel and 6 bolts.
     • Tighten to 80 Nm (59 lb-ft).
Fig 109: Flexplate Bolts
Courtesy of FORD MOTOR CO.