Part 1

Engine Front Cover














WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

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.

All vehicles

1. Install the Alignment Pins.





2. NOTICE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
- Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.






3. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 17, 18, 19 and 20.

- Tighten in sequence to 3 Nm (27 lb-in).






4. Remove the Alignment Pins.





5. NOTE: Do not tighten the bolts at this time.
Install the engine mount bracket and the 3 bolts.






6. 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 2 stages:
- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).

- Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).






7. NOTICE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.

Install the engine mount studs in the following sequence.
1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.

2. Clean all the thread sealer from the engine mount studs (old and new studs).

3. Apply new Threadlock and Sealer to the engine mount stud threads.

4. Install the 2 engine mount studs.
- Tighten to 20 Nm (177 lb-in).







8. Install the engine mount bracket and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).






9. 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.






10. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the crankshaft pulley.






11. 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.






12. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).






13. Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






14. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

NOTE: Spark plug tube seal installation shown, Variable Camshaft Timing (VCT) solenoid seal installation similar.
Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new VCT (Variable Camshaft Timing) solenoid and/or spark plug tube seals.





15. NOTICE: Failure to use Motorcraft 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 High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.






16. Using a new gasket, install the RH valve cover and tighten the bolt and 8 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






17. NOTICE: Failure to use Motorcraft 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 High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.






18. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






19. Install the wiring harness retaining bracket and the 2 nuts.
- Tighten to 4 Nm (35 lb-in).






20. Install the Power Steering Pressure (PSP) hose bracket and nut.
- Tighten to 9 Nm (80 lb-in).






21. Attach the PSP (Power Steering Pressure) hose retainer to the engine lifting eye.





22. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.

- Tighten to 7 Nm (62 lb-in).






23. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

24. Connect the 3 LH coil-on-plug electrical connectors.





25. Connect the LH camshaft VCT (Variable Camshaft Timing) solenoid electrical connector.





26. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

27. Connect the 3 RH coil-on-plug electrical connectors.





28. Connect the RH VCT (Variable Camshaft Timing) solenoid electrical connector.





29. Connect the PSP (Power Steering Pressure) switch electrical connector.





30. Connect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.





31. 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 the 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






32. Install the upper intake manifold support bracket bolt.
- Tighten to 10 Nm (89 lb-in).






33. Attach the wiring harness retainers to the upper intake manifold.





34. Connect the Throttle Body (TB) electrical connector.





35. Connect the PCV hose to the PCV valve.





36. If equipped, attach the block heater wiring harness retainer to the PSP (Power Steering Pressure) tube and the power steering reservoir hose.





37. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.





38. Raise the engine and transaxle assembly into the vehicle.

39. Install the engine mount, the nut and the 2 bolts.
- Tighten the bolts to 55 Nm (41 lb-ft).

- Tighten the nut to 63 Nm (46 lb-ft).






40. Install the 2 engine mount spacers and the 4 engine mount nuts.
- Tighten in the sequence shown to 70 Nm (52 lb-ft).






41. Install the transaxle support insulator bracket, bolt and the 2 nuts.
- Tighten to 80 Nm (59 lb-ft).






42. Install the transaxle support insulator through bolt and nut.
- Tighten to 90 Nm (66 lb-ft).






Front Wheel Drive (FWD) vehicles

43. NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
Install the RH catalytic converter support bracket and the 2 bolts.






44. Install the 2 catalytic converter support bracket nuts.
- Tighten to 40 Nm (30 lb-ft).

- Tighten the 2 catalytic converter support bracket bolts to 20 Nm (177 lb-in).






All-Wheel Drive (AWD) vehicles

45. NOTE: A new Power Transfer Unit (PTU) seal must be installed whenever the intermediate shaft is removed.

Install a new PTU (Power Transfer Unit) seal.

All vehicles

46. NOTE: Align the index marks on the subframe to the index marks on the underbody that were made during removal.
Using the Powertrain Lift, raise the subframe into the installed position.






47. NOTE: LH shown, RH similar.
Install the 2 front subframe nuts.

- Tighten to 150 Nm (111 lb-ft).






48. NOTE: LH shown, RH similar.
Position the subframe brackets and install the 4 bolts finger-tight.






49. NOTE: LH shown, RH similar.
Install the 2 rear subframe nuts.

- Tighten to 150 Nm (111 lb-ft).