Steps 71-141

Assembly

71. Install remaining engine front cover retaining bolts and stud bolts.







72. Tighten all engine front cover retaining bolts and stud bolts in sequence shown to 20-30 N.m (15-22 lb-ft).

73. If removed, install drive belt idler pulley onto RH side of engine front cover. Tighten drive belt idler pulley retaining bolt to 20-30 N.m (15-22 lb-ft).

74. Lubricate engine front cover crankshaft front oil seal bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Using Crankshaft Seal Replacer/Cover Aligner T88T-6701-A and Crankshaft Damper Replacer T74P-6316-B, install crankshaft front seal into engine front cover.

75. Turn engine assembly upside down on engine stand.

76. WARNING: EYE PROTECTION IS REQUIRED TO BE WORN DURING USE OF COMPRESSED AIR. FAILURE TO WEAR EYE PROTECTION COULD RESULT IN POSSIBLE PERSONAL INJURY.

Clean oil pan with suitable soap and water solution. Dry completely with compressed air.

77. Clean oil pan to cylinder block sealing surfaces on oil pan and cylinder block with shop towel and Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.












78. Install new oil pan gasket and apply 8 mm (0.31 inch) diameter bead of Black Silicone Rubber F4AZ-19562-B or equivalent sealant meeting Ford specification WSE-M4G323-A1 at two places as shown in the illustration.

79. Install oil pan and oil pan retaining bolts and studs to cylinder block loosely in locations shown.

80. Align oil pan to rear of cylinder block using a straightedge to 0.0-0.25 mm (0.0-0.010 inch). Install or remove shims from rear of oil pan as required.

81. With oil pan aligned to rear of cylinder block, tighten oil pan retaining bolts and studs in sequence to 20-30 N.m (15-22 lb-ft) in no more than six minutes after applying sealer.

82. Turn engine right side up on engine stand.

83. Install oil pressure sensor into cylinder block. Apply Pipe Sealant with Teflon© D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to oil pressure sensor prior to installation. Tighten oil pressure sensor to cylinder block to 12-16 N.m (9-12 lb-ft).

84. Lubricate oil bypass filter rubber seal with Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification ESE-M2C153-E and install oil bypass filter. Tighten oil bypass filter three-quarter turn after rubber seal contacts sealing surface.

85. NOTE: Inspect CMP and CKP sensor 0-ring prior to installation of sensors. Replace 0-ring as necessary if damaged or worn.

NOTE: Camshaft position (CMP) sensor has 90 degree angled exhaust manifold connector end.

If removed, install crankshaft position (CKP) sensor and camshaft position (CMP) sensor into engine front cover. Install and tighten sensor retaining bolts to 8-12 N.m (71-106 lb-in).







86. NOTE: Lubricate crankshaft front oil seal lip prior to installation of crankshaft pulley.

Install crankshaft pulley using Crankshaft Damper Replacer T74P-6316-B and washer from retaining bolt.

87. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.

NOTE: Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-Al must be applied to front of crankshaft on inside diameter of crankshaft pulley at keyway prior to installing crankshaft pulley retaining bolt.

Install crankshaft pulley retaining bolt and washer.

Tighten retaining bolt as follows:

- Tighten retaining bolt to 120 N.m (89 lb-ft).

- Loosen retaining bolt a minimum of one full turn.

- Tighten retaining bolt to 47-53 N-m (35-39 lb-ft).

- Rotate retaining bolt an additional 85-95 degrees.

88. Install power steering pump and brace onto engine front cover retaining studs.

89. Install power steering pump and brace to power steering pump bracket retaining bolts. Tighten retaining bolts to 20-30 N.m (15-22 lb-ft).

90. Install power steering pump brace to engine front cover stud retaining nuts. Tighten retaining nuts to 8-12 N.m (71-106 lb-in).







91. Install power steering pump pulley hub and retaining bolts to power steering pump. Tighten retaining bolts to 20-30 N.m (15-22 lb-ft).

92. NOTE: Factory supplied spark plugs are different from LH cylinder head to RH cylinder head. Install spark plugs F43E-12405-DA into RH cylinder head. Install spark plugs F43E-12405-CA into LH cylinder head. Replacement spark plugs are identical and can be installed in either cylinder head.

NOTE: Verify and correct if necessary spark plug electrode gap to 1.5 mm (0.060 inch) prior to installation.

Install spark plugs into cylinder heads. Tighten spark plugs to 9-20 N-m (7-15 lb-ft).

93. Using a suitable seal remover, remove camshaft rear oil seal from camshaft rear oil seal retainer.

94. Using a clean shop towel and Metal Brake Parts Cleaner F2ZZ-19579-AA or F3AZ-19579-SA or equivalent, clean cylinder head to camshaft rear oil seal retainer sealing surfaces.

95. Install camshaft rear oil seal inner gasket into groove.







96. Install camshaft rear oil seal retainer and new gasket and retaining bolts to LH cylinder head. Tighten retaining bolts to 8-12 N.m (71-106 lb-in).

97. Lubricate camshaft rear oil seal retainer seal bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.












98. Using Power Steering Pump Pulley Replacer T91P-3A733-A and Camshaft Seal Replacer T94P-6256-BH with Camshaft Seal Protector T94P-6256-AH, install camshaft rear oil seal into camshaft rear oil seal retainer.

99. Using a shop towel and Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-A, clean cylinder head to valve cover sealing surfaces to remove all residues that may interfere with the sealer's ability to adhere.

100. Apply 8 mm (0.31 inch) diameter bead of Black Silicone Rubber F4AZ-19562-B or equivalent sealant meeting Ford specification WSE-M4G323-A1 at two places on the valve cover sealing surfaces where the engine front cover and cylinder heads contact each valve cover. Also at two places on the LH cylinder head where the camshaft rear oil seal retainer contacts the LH cylinder head.







101. Install new valve cover gaskets (6584), valve covers and retaining bolts and studs. Verify bolts and studs are in their proper locations. Tighten in sequence to 8-12 N.m (71-106 lb-in).

102. Install ignition coil, radio ignition interference capacitor, ignition coil ground cable and ignition coil retaining bolts to RH valve cover. Tighten retaining bolts to 8 N.m (71 lb-in).

103. CAUTION: Water pump retaining bolts must be replaced with new bolts. They are torque-to-yield design and cannot be reused.

Install water pump and new torque-to-yield water pump retaining bolts onto LH cylinder head. Tighten new water pump retaining bolts to 15-18 N.m (11-13 lb-in), then rotate retaining bolts 85-95 degrees.












104. If removed, install water pump drive belt tensioner and retaining bolt to water pump. Tighten retaining bolt to 8-12 N.m (71-106 lb-in).

105. Lubricate water pump outlet hose with Silicone Lubricant C0AZ-19553-AA or D7AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A. Install water pump outlet hose onto cylinder block inlet tube. Install water pump outlet hose spring clamp securely.








106. NOTE: Inspect water crossover to cylinder block 0-ring for damage or wear. Replace as necessary.

Lubricate 0-ring with Silicone Lubricant COAZ-19553-AA or D7AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A and install 0-ring, water crossover and retainers on to RH cylinder head. Install retaining stud bolt in the upper water crossover bolt hole and bolt in lower hole. Tighten retainers to 8-12 N.m (71-106 lb-in).

107. Lubricate water pump inlet hose with Silicone Lubricant D7AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A. Install water pump inlet hose onto water crossover tube. Install water pump inlet hose spring clamp securely.







108. Install crankcase ventilation tube onto oil separator and water crossover stud bolt. Install crankcase ventilation tube retaining nut. Tighten nut to 5-7 N.m (44-62 lb-in).

109. Install new intake manifold gaskets onto cylinder heads using locating pins to position intake manifold gaskets.







110. Install lower intake manifold, fuel injectors and fuel injection supply manifold as an assembly onto cylinder heads.







111. Install lower intake manifold retaining bolts and tighten to 8-12 N.m (71-106 lb-in) in sequence shown.

112. Install main emission vacuum control connector onto fuel pressure regulator.












113. Install fuel charging wiring and in-line connector bracket onto RH valve cover retaining studs. Connect fuel charging wiring to the following components:

- Crankshaft position sensor.

- Oil pressure sensor.

- Camshaft position sensor.

- Fuel injectors

- Radio ignition interference capacitor.

- Ignition coil.

- Engine coolant temperature sensor.












114. Install new intake manifold upper gaskets onto lower intake manifold using locating pins to position intake manifold upper gaskets.

115. Install upper intake manifold and upper intake manifold retaining bolts onto lower intake manifold. Tighten retaining bolts in sequence to 8-12 N.m (71-106 lb-in).

116. If removed, install idle air control valve gasket, idle air control valve and retaining bolts onto upper intake manifold. Tighten retaining bolts to 5-7 N.m (44-62 lb-in), then rotate bolts 85-95 degrees.

117. If removed, install EGR vacuum regulator control and retaining bolts onto upper intake manifold. Tighten retaining bolts to 5-7 N.m (44-62 lb-in). Service and Repair

118. If removed, install throttle body gasket, throttle body and throttle body retaining bolts and stud bolt to upper intake manifold. Position stud bolt in lower RH bolt hole. Tighten throttle body retaining bolts to 8-12 N.m (71-106 lb-in). Service and Repair

119. Connect fuel charging wiring to idle air control valve, EGR vacuum regulator control and throttle position sensor.

120. If removed, install EGR valve gasket, EGR valve and EGR valve retainers. Tighten retainers to 20-30 N.m (15-22 lb-ft). Service and Repair

121. Install positive crankcase ventilation valve into oil separator crankcase ventilation tube and connect vacuum supply crankcase ventilation tube onto upper intake manifold vacuum port.







122. Install RH exhaust manifold gasket, RH exhaust manifold and exhaust manifold nuts onto RH cylinder head. Tighten exhaust manifold nuts to 18-22 N.m (13-16 lb-ft). Connect H02S to fuel charging wiring.

123. Install EGR valve to exhaust manifold tube to RH exhaust manifold and EGR valve. Tighten EGR valve to exhaust manifold tube nuts to 35-45 N.m (26-33 lb-ft).

124. Install EGR pressure sensor and mounting bracket assembly and bracket retainers onto RH cylinder head. Tighten retainers to 8-12 N.m (71-106 lb-in).







125. Install ignition coil ground cable and retaining nut onto EGR pressure sensor mounting bracket stud bolt. Tighten retaining nut to 5-7 N.m (44-62 lb-in).

126. NOTE: Using a hand vacuum pump, verify operation of intake manifold runner control (IMRC) vacuum solenoid and plate operation.

Connect EGR pressure sensor hoses to EGR valve to exhaust manifold tube.

127. Connect fuel charging wiring to EGR pressure sensor and control solenoid vacuum valve.







128. Install main emission vacuum control connector onto upper intake manifold vacuum port, EGR valve, EGR vacuum regulator control, control solenoid vacuum valve, IMRC solenoid and fuel pressure regulator vacuum connector.







129. NOTE: Inspect oil level indicator tube to lower cylinder block 0-ring for damage or wear. Replace 0-ring as necessary. Lubricate oil level indicator tube 0-ring with Silicone Lubricant COAZ-19553-AA or D7AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A. Install oil level indicator tube, oil level dipstick and oil level indicator tube retaining bolt. Tighten retaining stud bolt to 8-12 N.m (71-106 lb-in).

130. Install LH exhaust manifold gasket, LH exhaust manifold and exhaust manifold nuts onto LH cylinder head. Tighten exhaust manifold nuts to 18-22 N.m (13-16 lb-ft).







131. NOTE: Install water pump drive pulley on camshaft until pulley hub is flush with end of camshaft.

Using Power Steering Pump Pulley Replacer T91P-3A733-A, Screw T94P-6312-AH and Replacer Cup T94P-6312-AH or equivalent, install water pump drive pulley on LH intake camshaft.

132. Rotate water pump drive belt tensioner clockwise and install water pump drive belt. Carefully release drive belt tensioner.

133. NOTE: LH engine lifting eye is retained to cylinder head with stud bolt.

Install engine lifting eyes onto RH and LH cylinder heads. Tighten engine lifting eye retainer bolts to 40-55 N.m (29-40 lb-ft).

134. NOTE: Generator mounting bracket aligns to cylinder block with hollow alignment dowels.

Install generator mounting bracket and retaining bolts to cylinder block and engine front cover.

Tighten retaining bolts to 20-30 N.m (15-22 lb-ft).







135. Install generator and retaining bolt to generator mounting bracket. Tighten retainer bolt to 40-55 N.m (29-40 lb-ft).

136. Install generator brace onto generator mounting bracket and generator. Install and tighten retaining bolts to 20-30 N.m (15-22 lb-ft).







137. Install A/C compressor and retaining bolts. Tighten retaining bolts to 20-30 N.m (15-22 lb-ft).

138. Connect ignition wires to spark plugs and ignition coil. Install ignition wire separators onto upper intake manifold. Service and Repair

139. Rotate accessory drive belt tensioner clockwise and install accessory drive belt. Carefully release drive belt tensioner.

140. Tighten four power steering pump pulley retaining bolts to 20-30 N.m (15-22 lb-ft).

141. Remove engine from engine stand using Rotunda Powertrain Lift 014-00765 or equivalent.