Part 2

Engine




















a Early build vehicle cooling systems are filled with Motorcraft(R) Specialty Green Engine Coolant and late build vehicle cooling systems are filled with Motorcraft(R) Specialty Orange Engine Coolant. Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.

Lower Engine Block (View 1)










Lower Engine Block (View 2)










Front Engine Block










Cylinder Head










Intake Manifold









NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can 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.

31. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.
Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:

- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).






32. Install a new gasket, oil pump pickup tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






33. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear main oil seal.





34. Tighten the 6 crankshaft rear main oil seal retainer plate bolts in the sequence shown.
- To install, tighten to 10 Nm (89 lb-in).







35. 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. Use a plastic scraping tool to remove traces of sealant.

Clean and inspect all mating surfaces.


36. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow these instructions can cause future oil leakage.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.

- Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.






37. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.





38. Install the remaining oil pan bolts.
- Tighten in the sequence shown to 20 Nm (177 lb-in).






39. Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.





40. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.

2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.

3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.


41. Apply silicone gasket and sealant to the locations shown.





42. Install a new head gasket.





43. NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. New cylinder head bolts must be installed.

NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the cylinder head and 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: Turn 90 degrees.

- Stage 5: Turn an additional 90 degrees.






44. NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.


45. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate 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.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts and bearing caps in their original locations and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
- Stage 1: Tighten the camshaft bearing cap bolts until finger-tight.

- Stage 2: Tighten to 7 Nm (62 lb-in).

- Stage 3: Tighten to 16 Nm (142 lb-in).






46. Install the Variable Camshaft Timing (VCT) system oil filter and the plug in the intake camshaft thrust cap.
- Tighten to 17 Nm (150 lb-in).






47. Install the Variable Camshaft Timing (VCT) solenoid and the bolt.
- Tighten to 10 Nm (89 lb-in).






48. NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
Install the crankshaft sprocket and new crankshaft sprocket diamond washers.

- The crankshaft sprocket flange must be facing away from the engine block.






49. Install the oil pump drive chain, sprocket and bolt.
- Tighten to 25 Nm (18 lb-ft).






50. Install the oil pump drive chain tensioner shoulder bolt.
- Tighten to 10 Nm (89 lb-in).






51. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
- Tighten to 10 Nm (89 lb-in).






52. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.






53. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.





54. Install the timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






55. Install the timing chain.





56. Install the timing chain tensioner arm.





NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

57. 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.






58. Using a small pick, push back and hold the ratchet mechanism.





59. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





60. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.





61. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston.
- Tighten to 10 Nm (89 lb-in).






62. NOTICE: The Camshaft Alignment Plate 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 camshaft sprocket bolts.
- Tighten to 72 Nm (53 lb-ft).






63. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs 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.


64. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.






65. Install the engine front cover. Tighten the 22 bolts in the sequence shown, to the following specifications:
- Tighten the 8-mm bolts to 10 Nm (89 lb-in).

- Tighten the 13-mm bolts to 48 Nm (35 lb-ft).






66. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.
Using the Camshaft Front Oil Seal Installer, install a new crankshaft front oil seal.






67. 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 hole in the pulley at the 6 o'clock position.






68. NOTICE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.






69. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) 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 Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).

- Stage 2: Tighten an additional 90 degrees (one-fourth turn).






70. Remove the 6 mm x 18 mm bolt.