Part 3
Engine
Engine Upper
Engine Front
Engine Lower (View 1)
Lower Engine (View 2)
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
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.
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
NOTE: The Differential Bearing Cone Installer is used to install the Variable Camshaft Timing (VCT) solenoid seals.
96. Remove the Alignment Pins.
97. NOTE: Do not tighten the bolt at this time.
Install the M6 engine front cover bolt.
98. NOTE: Do not tighten the bolts at this time.
Install the 3 M10 engine front cover bolts.
99. NOTICE: Do not expose the Motorcraft(R) 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 7 stages:
- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 23, 24 and 25 to 15 Nm (133 lb-in).
- Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in).
- Stage 4: Loosen bolt 26 one full turn.
- Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees.
- Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees.
- Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.
100. NOTE: Installation of new seals is only required if damaged seals were removed.
NOTE: RH shown, LH similar.
Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
101. NOTE: Installation of new seals is only required if damaged seals were removed.
NOTE: RH shown, LH similar.
Using the Differential Bearing Cone Installer and Handle, install new VCT (Variable Camshaft Timing) solenoid seal(s).
102. 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-RH cylinder head joints.
103. Using a new gasket, install the RH valve cover and tighten the 4 bolts and 7 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
104. Make sure 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.
105. Install the 3 RH -coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).
106. NOTICE: Failure to use 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.
107. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
108. Make sure 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.
109. Install the 3 LH -coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in.
110. 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.
111. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP (Engine Oil Pressure) switch.
- Tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.
112. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
113. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
114. NOTE: Apply clean engine coolant to the O-ring seal prior to installation.
Using a new O-ring seal, install the coolant inlet tube and thermostat assembly.
115. 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 intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
116. Install the 2 thermostat housing-to-lower intake manifold bolts.
- Tighten to 10 Nm (89 lb-in).
117. NOTE: Lubricate the 2 Camshaft Position (CMP) sensor O-ring seals with clean engine oil.
Install the 2 RH CMP (Camshaft Position) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
118. NOTE: Lubricate the 2 CMP (Camshaft Position) sensor O-ring seals with clean engine oil.
Install the 2 LH CMP (Camshaft Position) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
119. Install the cover and the pin-type retainer.
120. If equipped, install the block heater wiring harness onto the engine.
- 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).
121. Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
122. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
123. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
NOTE: Heat shield removed from graphic for clarity.
Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
Front Wheel Drive (FWD) vehicles
124. Using a new gasket, install the RH catalytic converter and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).
All vehicles
125. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
126. Using a new gasket, install the LH catalytic converter and 3 new lower LH catalytic converter manifold-to-cylinder head nuts.
- Install the 3 new upper LH catalytic converter manifold-to-cylinder head nuts and tighten to 25 Nm (18 lb-ft).
- Tighten the 3 lower LH catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).
127. Install the LH exhaust heat shield and the 3 bolts.
Tighten to 12 Nm (106 lb-in).
128. NOTE: Apply anti-seize to the threads of the HO2S (Heated Oxygen Sensor) prior to installing.
Install the LH HO2S (Heated Oxygen Sensor).
- Tighten to 48 Nm (35 lb-ft).
129. NOTE: Power steering hoses removed from graphic for clarity.
Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
130. Position the 2 power steering hose brackets and install the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
131. Install the generator, the bolt and the nut.
- Tighten to 47 Nm (35 lb-ft).
132. Position the wiring harness onto the engine.
133. Connect the EOP (Engine Oil Pressure) switch electrical connector and the wiring harness pin-type retainer.
134. Attach the wiring harness retainer to the generator.
135. Connect the generator electrical connector.
