Part 4
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
Lower Engine Block (View 1)
Lower Engine Block (View 2)
NOTICE: 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: 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.
130. NOTICE: Failure to use the correct Motorcraft(R) 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 this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
131. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
132. Ensure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the VCT (Variable Camshaft Timing) oil control solenoid electrical connector or the VCT (Variable Camshaft Timing) seal may leak oil.
133. NOTICE: Only use hand tools when installing the spark plugs, or damage may occur to the cylinder head or spark plug.
Install the 3 LH spark plugs.
- Tighten to 15 Nm (133 lb-in).
134. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
- To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
135. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).
136. NOTE: Lubricate the O-ring seal with clean engine coolant.
Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7 bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
137. Install the coolant pump pulley and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).
138. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.
Install the thermostat housing and the 4 bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
139. Attach the heater tube retainer to the RH valve cover stud bolt.
140. Install the heater tube bolt.
- Tighten to 23 Nm (17 lb-ft).
141. Install the RH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
142. Install the LH 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).
143. Install the accessory drive belt tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
144. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
145. Lubricate the crankshaft front seal inner lip with clean engine oil.
146. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.
147. 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.
148. Install the generator stud and position the generator and install the nut and bolt.
- Tighten the stud to 8 Nm (71 lb-in).
- Tighten the nut and bolt to 48 Nm (35 lb-ft).
149. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
150. Connect the CKP (Crankshaft Position) sensor electrical connector.
151. Install the wiring harness grommet.
152. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).
153. Install the heat shield, the nut and the bolt.
- Tighten to 10 Nm (89 lb-in).
154. Connect the 2 LH CMP (Camshaft Position) sensors electrical connectors.
- Attach the wiring harness retainer to the rear of the cylinder head.
155. Connect the KS (Knock Sensor) sensor electrical connector.
156. Connect the 2 LH VCT (Variable Camshaft Timing) solenoid electrical connectors.
157. Connect the 3 LH fuel rail electrical connectors.
158. Connect the 3 LH ignition coil-on-plug electrical connectors.
159. Connect the Engine Oil Pressure (EOP) switch electrical connector.
- Attach the EOP (Engine Oil Pressure) switch wiring harness retainer to the cylinder head.
160. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
161. Connect the 2 RH CMP (Camshaft Position) sensors electrical connectors.
162. Connect the 2 RH VCT (Variable Camshaft Timing) solenoid electrical connectors.
163. Connect the 3 RH fuel rail electrical connectors.
164. Connect the CHT (Cylinder Head Temperature) sensor wiring harness jumper electrical connector.
165. Connect the 3 RH ignition coil-on-plug electrical connectors.
166. Install the RH fuel rail insulator.
167. NOTICE: 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.
Using new gaskets, install the upper intake manifold and tighten the 7 bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
168. Install the upper intake manifold support bracket bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).
169. Install the LH fuel rail insulator.
170. Attach the wiring harness pin-type retainer to the rear of the upper intake manifold.
171. Connect the PCV tube quick connect couplings to the PCV valve and intake manifold.
172. Connect the Throttle Body (TB) electrical connector.
- Attach the TB (Throttle Body) electrical connector wiring harness pin-type retainer to the TB (Throttle Body).
173. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
- Attach the EVAP (Evaporative Emission) canister purge valve electrical connector wiring harness pin-type retainer.
174. Install the engine oil level indicator.
175. Install the crankcase vent tube.
176. Install the LH engine lift eye.
177. Install the RH front lift eye.
178. Using the Floor Crane and Spreader Bar, remove the engine from the stand.
179. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
180. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
181. Install the crankshaft sensor ring.
182. NOTE: Flexplate shown, flywheel similar.
Install the spacer plate.
Engines with manual transmission
183. NOTE: The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).
Install the flywheel and the 8 bolts and tighten is sequence shown.
- Tighten to 80 Nm (59 lb-ft).
184. NOTE: If installing the original pressure plate, align it using the index marks made during removal.
NOTE: Always install new pressure plate bolts.
Using a suitable clutch aligner, position the clutch disc on the flywheel, install the pressure plate and 6 new pressure plate bolts. Turn the bolts 1-2 turns at a time in a star pattern until the clutch is fully secured.
- Tighten the pressure plate bolts in 2 stages in a star pattern
- Stage 1: Tighten to 47 Nm (35 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
Engines with automatic transmission
185. Install the flexplate and the 8 bolts and tighten is sequence shown.
- Tighten to 80 Nm (59 lb-ft).
