Part 3

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.

71. Remove the Crankshaft TDC (Top Dead Center) Timing Peg.





72. Remove the Camshaft Alignment Plate.





73. NOTE: Only turn the engine in the normal direction of rotation.
Turn the crankshaft clockwise one and three-fourths turns.


74. Install the Crankshaft TDC (Top Dead Center) Timing Peg.





75. NOTE: Only turn the engine in the normal direction of rotation.
Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC (Top Dead Center) Timing Peg.






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

Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, the engine valve timing must be corrected.






77. Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.






78. Remove the Camshaft Alignment Plate.





79. Install the Crankshaft Position (CKP) sensor and the 2 bolts.
- Do not tighten the bolts at this time.






80. Using the Crankshaft Sensor Aligner, adjust the CKP (Crankshaft Position) sensor.
- Tighten the 2 CKP (Crankshaft Position) bolts to 7 Nm (62 lb-in).






81. Remove the 6 mm x 18 mm bolt.





82. Remove the Crankshaft TDC (Top Dead Center) Timing Peg.





83. Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).






84. 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 the valve cover gasket surface with metal surface prep.


85. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.
Apply silicone gasket and sealant to the locations shown.






86. Install the valve cover.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).






87. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
Install the 4 coil-on-plugs and the 4 bolts.

- Tighten to 8 Nm (71 lb-in).






88. NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.
Install the oil level indicator.






89. If equipped, install the block heater.
- Tighten to 40 Nm (30 lb-ft).






90. Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).






91. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
Install the KS (Knock Sensor) and the bolt.

- Tighten to 20 Nm (177 lb-in).






92. Install the coolant bypass hose on the coolant outlet.





93. Connect the coolant bypass hose.





94. Install the EGR tube.
- Tighten to 55 Nm (41 lb-ft).






95. 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.

Position the intake manifold and connect the crankcase vent oil separator tube.