Part 4

Engine














Upper End Components and Front End Accessory Drive (FEAD) Components










Lower End Components and Coolant Pump










Oil Filter Adapter Assembly










Timing Drive Components and Cylinder Heads










Flywheel and Exhaust Manifolds









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, can cause engine failure.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play.

120. Install the generator and the 3 bolts.
- Tighten to 50 Nm (37 lb-ft).






121. Connect the B+ wire to the generator and install the nut.
- Tighten to 8 Nm (71 lb-in).






122. Connect the generator electrical connector.





123. Position the SC (Supercharger) drive belt and install the SC (Supercharger) drive belt tensioner and bolt.
- Tighten to 48 Nm (35 lb-ft).






124. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.





125. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).





126. Connect the coolant hose from the Charge Air Cooler (CAC).





127. Install the thermostat housing assembly and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).






128. Connect the 2 upper radiator hoses to the intake manifold.





129. Install the coolant tube bracket nut.
- Tighten to 9 Nm (80 lb-in).






130. Connect the coolant hose to the thermostat housing.





131. Install the Engine Lifting Bracket.





132. Install the Engine Lifting Bracket.





133. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, remove the engine from the work stand.





134. Apply a 4 mm (0.15 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating surface on the engine block.





135. NOTICE: If not secured 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Install the crankshaft rear seal retainer plate and the 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






136. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear seal.






137. Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear seal.





138. Install the oil pump screen and pickup tube spacer.
- Tighten to 25 Nm (18 lb-ft).






139. 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 all traces of old sealant.

NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Clean and inspect the mating surfaces of the engine block and oil pan.


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

NOTE: If the oil pan is not installed and the fasteners tightened within 5 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. If this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque all of the fasteners within 1 hour of applying the sealer.
Apply an 8 mm (0.31 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.






141. Position the oil pan baffle and gasket.





142. NOTE: The 2 oil pump screen and pickup tube-to-oil pump bolts must be tightened prior to tightening the oil pump screen and pickup tube-to-spacer bolt.
Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts.

- Tighten to 10 Nm (89 lb-in).






143. Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).

144. 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 all traces of old sealant.

NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

NOTE: Fastener locations 11, 12 and 13 are stud bolts.

Install the oil pan, 13 bolts and 3 stud bolts.
- Tighten in the sequence shown to 25 Nm (18 lb-ft).






145. Attach the wiring harness retainer and install the 2 wiring harness brackets and the 2 nuts to the oil pan stud bolts.
- Tighten to 10 Nm (89 lb-in).






146. Install the engine/transmission spacer plate.





147. Position the flywheel on the crankshaft pilot and start the 8 flywheel bolts.

148. Tighten the flywheel bolts evenly in the sequence shown to fully seat the flywheel on the crankshaft pilot.
- Tighten to 80 Nm (59 lb-ft).