Steps 61-116
61. Verify timing index marks on timing chain are in alignment with timing index marks on crankshaft sprocket, engine balance shaft driven gear and camshaft sprockets.
62. Install power steering pump to power steering pump support with three retaining bolts. Tighten to 18-28 Nm (14-20 ft. lbs.)
63. Install crankshaft position (CKP) sensor pulse ring onto crankshaft. Align crankshaft key with keyway on CKP sensor pulse ring.
64. Clean engine front cover to cylinder block and cylinder head sealing surfaces using a clean shop towel and Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A, to remove all residues that may interfere with the sealer's ability to adhere.
65. NOTE: Install engine front cover, retaining bolts and stud bolts in the locations and sequence shown, no more than six minutes after applying sealer.
Fig. 12 Engine Front Cover Sealer Locations:
Apply a bead 3 mm (0.118 inch) diameter and approximately 12 mm (0.472 inch) long, of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent sealant meeting Ford specification WSE-M4G323-A6 in eight gasket surface joints and five mounting bosses on cylinder block as shown.
Fig. 13 Engine Front Cover Installation:
66. Install engine front cover with new engine front cover gaskets over alignment dowels to cylinder block and cylinder heads.
67. Install engine front cover retaining bolts and stud bolts.
Fig. 14 Engine Front Cover Bolt Tightening Sequence:
68. Tighten all engine front cover retaining bolts and stud bolts in sequence shown to 18-28 Nm (14-20 ft. lbs.)
69. Lubricate engine front cover crankshaft front oil seal bore with Super Premium SAE SW30 Motor Oil XC-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Using Crankshaft Seal Replacer/ Cover Aligner 303-336 (T88T-6701-A), install crankshaft front seal into engine front cover.
70. Turn engine assembly upside down on engine stand.
71. WARNING: EYE PROTECTION IS REQUIRED TO BE WORN DURING USE OF COMPRESSED AIR. FAILURE TO WEAR EYE PROTECTION COULD RESULT IN PERSONAL INJURY.
Clean oil pan with suitable soap and water solution. Dry completely with compressed air.
72. Clean oil pan-to-cylinder block sealing surfaces on oil pan and cylinder block with shop towel and Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
73. Apply a 4 mm (0.16 inch) bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent sealant meeting Ford specification WSE-M4G323-A6 on the entire oil pan sealing surface where the oil pan, engine front cover and cylinder block contact.
Fig. 17 Oil Pan Bolt Tightening Sequence:
74. Install oil pan and retaining bolts to cylinder block. Tighten retaining bolts in sequence to 18-28 Nm (14-20 ft. lbs.), no more than six minutes after applying sealer.
75. Turn engine right side up on engine stand.
76. Install new oil filter adapter gasket and oil filter adapter to cylinder to lock with three retaining bolts. Align projection on oil filter adapter with locator tab on engine oil cooler and install engine oil cooler to oil filter adapter with oil cooler mounting bolt insert. Tighten oil cooler mounting bolt insert to 40-49 Nm (30-36 ft. lbs.)
77. Install oil pressure sender into oil filter adapter. Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to oil pressure sender prior to installation. Tighten oil pressure sender to oil filter adapter to 21-31 Nm (16-22 ft. lbs.)
78. Lubricate oil filter rubber seal with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G and install oil filter. Tighten oil filter three-quarter turn after rubber seal contacts sealing surface.
79. If removed, install crankshaft position (CKP) sensor into engine front cover. Install and tighten sensor retaining bolt to 8-12 Nm (71-106 inch lbs.)
80. Install camshaft position sensor into LH cylinder head. Install and tighten sensor retaining bolt to 8-12 Nm (71-106 inch lbs.)
81. NOTE: Lubricate crankshaft front oil seal lip prior to installation of crankshaft pulley.
Install crankshaft pulley using Vibration Damper and Seal Replacer 303-175 (T82L-6316-A) and washer from crankshaft pulley bolt.
82. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A, to remove all residues that may interfere with the sealer's ability to adhere.
NOTE: Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 must be applied to front of crankshaft on inside diameter of crankshaft pulley at keyway prior to installing crankshaft pulley retaining bolt.
Install crankshaft pulley bolt and washer. Tighten retaining bolt as follows:
- Tighten crankshaft pulley bolt to 105-135 Nm (78-99 ft. lbs.)
- Loosen crankshaft pulley bolt a minimum of one full turn.
- Tighten crankshaft pulley bolt to 47-53 Nm (35-39 ft. lbs.)
- Rotate crankshaft pulley bolt an additional 85-95 degrees.
83. Install power steering pump pulley, plain washer, split washer and retaining nut to power steering pump. Tighten to 55-69 Nm (41-50 ft. lbs.)
1 Of 2:
2 Of 2:
84. If removed, install drive belt tensioner pulleys. Tighten bolts to 36-62 Nm (27-38 ft. lbs.)
85. NOTE: Verify spark plug electrode gap to 1.11-1.16 mm (0.042-0.046 inch) prior to installation. Correct if necessary.
Install spark plugs into cylinder heads. Tighten spark plugs to 14-21 Nm (11- 15 ft. lbs.)
86. Using a shop towel and Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A, clean cylinder head to valve cover sealing surfaces to remove all residues that may interfere with the sealer's ability to adhere.
87. Apply 8 mm (0.31 inch) diameter bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent sealant meeting Ford specification WSE-M4G323-A6 at two places on the valve cover sealing surfaces where the engine front cover and cylinder heads contact each valve cover. Also apply silicone rubber at two places on the rear of the LH cylinder head and where the camshaft rear oil seal retainer contacts the LH cylinder head.
88. Install valve cover gaskets, valve covers and retaining bolts and studs. Verify bolts and studs are in their proper locations. Tighten to 8-12 Nm (71-106 inch lbs.)
89. Install ignition coil and retaining bolts. Tighten bolts to 8-12 Nm (71-106 inch lbs.)
90. Install water outlet fitting and wire clamp to cylinder block with new gasket. Tighten four retaining bolts.
91. Install oil cooler water bypass inlet and outlet hoses to oil cooler with clamps.
92. Install RH and LH water bypass hoses and water bypass tee fitting to water bypass pipes on RH and LH cylinder head.
93. If removed, install water pump belt idler pulley and retaining bolt to water pump. Tighten retaining bolt to 10-16 Nm (89-141 inch lbs.)
94. Install water pump drive pulley to camshaft with three retaining bolts. Tighten bolts to 10-16 Nm (89-141 inch lbs.)
95. Place drive belt over water pump drive pulley.
96. Lubricate water pump inlet hose, outlet hose and O-rings with Ford Extended Life Engine Coolant F6AZ-19544-AA or DEX-COOL-equivalent that meets Ford specification WSS-M97B44-D.
97. Install water pump inlet hose between water pump and water inlet connection. Secure with two clamps.
98. Connect water pump to water outlet hose and install to RH and LH cylinder heads with O-rings and retaining bolts. Tighten four retaining bolts at cylinder head water inlets to 8-12 Nm (71-106 inch lbs.)
99. Retain water pump to LH cylinder head with two bolts and collar. Tighten bolts to 18-28 Nm (14-20 ft. lbs.)
100. Connect heater core to water pump return hose and oil cooler to water pump return hose to water pump.
101. Install lower intake manifold, fuel injectors and fuel injection supply manifold as an assembly onto cylinder heads.
102. Install engine control sensor wiring and wire clamps onto engine. Connect engine control sensor wiring to the following components:
- crankshaft position sensor
- accelerator cable bracket
- camshaft position sensor
- fuel injector
- radio ignition interference capacitor
- ignition coils
- engine coolant temperature sensor
- water temperature indicator sender unit
- engine control sensor extension wiring
- Intake Manifold Runner Control (IMRC) deactivation motor
103. Install exhaust manifolds.
104. Install secondary air injection diverter valve, exhaust air supply valve mounting bracket and exhaust air supply tube to exhaust manifolds and RH cylinder head.
105. Install upper intake manifold.
106. If removed, install the following components:
- idle air control valve
- transducer mounting bracket
- Throttle Body Gasket (TB gasket)
- throttle position sensor
- EGR valve
107. Install positive crankcase ventilation valve into oil separator crankcase ventilation tube and connect vacuum supply crankcase ventilation tube onto upper intake manifold vacuum port.
108. Install oil level indicator tube.
109. CAUTION: Use extreme care to keep coolant mixture off of the drive belt and pulleys. If needed, remove drive belt and rinse with clear water. Clean pulleys and install drive belt. Belt squeal and early belt fatigue will occur otherwise.
Rotate water pump drive belt tensioner clockwise and install water pump drive belt. Carefully release drive belt tensioner.
110. Install water pump to throttle body return and supply hoses.
111. Install Rotunda 3.4L-SHO Engine Lifting Brackets 303-F055 (014-00797) or equivalent onto RH and LH cylinder heads.
112. Install generator mounting bracket and retaining bolts to cylinder block.
Generator And Bracket, Removal:
113. Install generator to generator bracket.
114. Install A/C compressor and retaining bolts. Tighten retaining bolts to 23-37 Nm (17-27 ft. lbs.)
115. Rotate accessory drive belt tensioner clockwise and install accessory drive belt. Carefully release drive belt tensioner.
116. Remove engine from engine stand using Rotunda Powertrain Lift 014-00765 or equivalent.