Part 2
Engine
35. Install a new cylinder head gasket.
36. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
Install the cylinder head and the 10 new bolts.
- Tighten the bolts in the sequence shown in 5 stages.
- Stage 1: Tighten to 7 Nm (62 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten an additional 90 degrees.
37. NOTE: Lubricate the valve tappets with clean engine oil prior to installing.
Install the 16 valve tappets in their original positions.
38. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the 303-1565 can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
Lubricate the cylinder head and camshaft journals with clean engine oil and position the camshafts onto the cylinder head in their original location and orientation.
39. NOTE: The exhaust camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
NOTE: Do not allow Gasket Maker to enter the camshaft bearing journal. If Gasket Maker is applied to the camshaft bearing journal, the journal and sealing area must be cleaned with Motorcraft(R) Metal Surface Prep.
Apply a 1 mm (0.0394 in) bead of Gasket Maker to the exhaust camshaft rear bearing cap as shown.
40. NOTICE: Failure to follow the camshaft bearing cap tightening procedure can result in damage to the camshafts.
NOTE: Lubricate the bearing cap journals with clean engine oil prior to installation.
Install the camshaft bearing caps in their original location and orientation and tighten the camshaft bearing cap bolts in pairs in the sequence shown in 2 stages:
- Stage 1: Tighten to 7 Nm (62 lb-in).
- Stage 2: Tighten to 16 Nm (142 lb-in).
41. If camshafts were replaced, check that the camshaft end play is within specification. REFER to Camshaft End Play .
42. If camshafts were replaced, check the valve clearance. REFER to Valve Clearance Check .
43. NOTICE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
Install 303-1565 into the rear of both of the camshaft slots as shown and tighten the retainer.
44. NOTE: Lubricate the VCT (Variable Camshaft Timing) oil control solenoids with clean engine oil.
Install the 2 VCT (Variable Camshaft Timing) oil control solenoids and tighten the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
45. NOTE: The VCT (Variable Camshaft Timing) phaser and sprocket bolts are final torqued in the timing drive installation.
Position the exhaust and intake VCT (Variable Camshaft Timing) phaser and sprockets and install the bolts finger tight.
46. Install the timing chain onto the 2 camshaft phaser and sprockets and the crankshaft sprocket.
47. Install the LH (Left Hand) timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
48. Install the timing chain tensioner arm.
49. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Using the edge of a vise, compress the timing chain tensioner plunger.
50. Using a small pick, push back and hold the ratchet mechanism.
51. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
52. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
53. Install the timing chain tensioner and the 2 bolts, then remove the paper clip to release the piston.
- Tighten to 10 Nm (89 lb-in).
54. NOTICE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
Using the flats on the camshafts to prevent camshaft rotation, tighten the 2 VCT (Variable Camshaft Timing) phaser and sprocket bolts in 2 stages.
- Stage 1: Tighten the bolt to 50 Nm (37 lb-ft)
.
- Stage 2: Tighten an additional 90 degrees
.
55. NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Clean and inspect the mounting surfaces of the engine and the front cover.
56. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
Apply a 15 mm (0.59 in) bead of Silicone Gasket and Sealant to the cylinder head and oil pan joint areas.
57. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
Apply a 3 mm (0.1181 in) bead of Silicone Gasket and Sealant to the sealing surface of the front cover. Apply a 2 mm (0.0787 in) bead of Silicone Gasket and Sealant to the 4 center sealing surface of the front cover.
58. Position the engine front cover and tighten the 22 engine front cover bolts in the sequence shown.
- Tighten bolts 1 through 17 to 10 Nm (89 lb-in).
- Tighten bolts 19 through 21 to 48 Nm (35 lb-ft).
- Tighten bolt 22 to 25 Nm (18 lb-ft).
- Tighten bolt 18 to 48 Nm (35 lb-ft).
59. NOTE: Remove the through-bolt from 303-096 (T74P-6150-A).
NOTE: Lubricate the oil seal with clean engine oil.
Using 303-096 (T74P-6150-A) , install the crankshaft front oil seal.
60. Install a new diamond washer onto the crankshaft.
61. NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
Position the crankshaft pulley onto the crankshaft with the crankshaft pulley TDC (Top Dead Center) guide hole at the 6 o'clock position.
62. NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
Install a standard bolt through the crankshaft pulley TDC (Top Dead Center) guide hole and into the engine front cover TDC (Top Dead Center) guide hole.
63. NOTICE: The crankshaft must remain in the TDC (Top Dead Center) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the 303-D055 (D85L-6000-A) and a new bolt should be installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Use the 303-D055 (D85L-6000-A) to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
-
- Stage 1: Tighten to 100 Nm (74 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
64. Remove the standard bolt from the crankshaft pulley TDC (Top Dead Center) guide hole.
65. Install the CKP (Crankshaft Position) sensor and the 2 bolts.
- Do not tighten the bolts at this time.
66. Install 303-1521 to set the CKP (Crankshaft Position) sensor position and tighten the 2 bolts.
- Tighten to 7 Nm (62 lb-in).
67. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
Clean and inspect the sealing surfaces.
68. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
Using the 205-153 (T80T-4000-W) and 303-1247/2 , install new VCT (Variable Camshaft Timing) solenoid seals.
69. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
Apply a 6 mm (0.2362 in) bead of Silicone Gasket and Sealant to the cylinder head and engine front cover joint areas.
70. Using a new valve cover gasket, install the valve cover and tighten the 14 retainers in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
71. If equipped, install the 4 engine appearance cover mounting stud.
- Tighten to 3 Nm (27 lb-in).
72. Inspect the ignition coil boot for rips, nicks or tears. Remove and discard the damaged ignition coil boots.
73. NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inside of the ignition coil-on-plug boots before installation.
Install the ignition coil-on-plug assemblies and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
74. Install the oil indicator.
75. Install the coolant outlet and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
76. Install the fuel injection pump cover and the 3 stud bolts and tighten in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 60 degrees.
77. Install the wiring harness support brackets and the 3 nuts.
- Tighten to 20 Nm (177 lb-in).
78. NOTE: The cam lobe for the fuel injection pump must be at BDC (Bottom Dead Center) for the fuel injection pump installation.
Lubricate the fuel injection pump tappet and the fuel injection pump cover bore with clean engine oil and install the fuel injection pump tappet.
79. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.
Lubricate the new O-ring seal with clean engine oil and install on the fuel injection pump.
80. NOTICE: Only rotate the crankshaft clockwise or damage to the engine may occur.
Using the crankshaft pulley bolt, turn the crankshaft clockwise until the fuel injection pump cam lobe is at BDC (Bottom Dead Center).
81. Install the fuel injection pump and loosely install 2 new fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated. Tighten the 2 fuel injection pump bolts in the following 2 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 45 degrees.
82. Install the intermediate shaft bearing bracket and the 3 bolts.
- Tighten to 48 Nm (35 lb-ft).
83. Install the catalytic converter support bracket and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
84. NOTICE: The RH (Right Hand) KS (Knock Sensor) must be installed in the 6 o'clock position and the LH (Left Hand) KS (Knock Sensor) must be installed in the 4 o'clock position. Failure to follow these instructions may result in damage to the engine.
Using the marked location, install the KS (Knock Sensor) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).
85. Using a new gasket, install the oil filter adapter and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
86. Using a new gasket, install the crankcase vent separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).
87. NOTICE: Do not attempt to cut the lower Teflon(R) 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(R) seals, not to scratch, nick or gouge the fuel injectors.
Pull the lower Teflon(R) seal away from the injector with narrow tip pliers.
88. Carefully cut and discard the lower fuel injector Teflon(R) seals.
89. Place the 303-1567 , knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
