Steps 59 - 116

59. NOTE: Use the crankshaft pulley bolt washer for installation.





Using the special tools, install the crankshaft pulley.
1 Position the pulley.
2 Install the special tools, install the pulley.





60. Install the crankshaft pulley
- Use Black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6 and seal the keyway in the pulley.
1 Use the a suitable strap wrench to hold the crankshaft pulley.
2 Tighten the crankshaft pulley bolt in four stages.
- Stage 1: 120 Nm
- Stage 2: Back off bolt one full turn
- Stage 3: 50 Nm
- Stage 4: 90 degrees





61. Install the power steering pump and bracket.
- Loosely install all bolts and studs.

62. NOTE: The longer 84 mm bolts should be tightened first.





Tighten the power steering pump bolts.





63. Tighten the power steering pump stud nuts.

64. CAUTION: Tightening pulley with dimple facing power steering pump will bend the pulley.

NOTE: The dimple on pulley must face toward the front of the engine.





Install the power steering pump belt pulley.





65. Install the camshaft oil seal retainer.
- Install a new gasket and align the retainer on the locating dowels.

66. CAUTION: The running surface of the camshaft must not be damaged.

NOTE: Lubricate the seal with engine oil.





Using the special tools, install the camshaft oil seal.
1 Install special tool.
2 Position a new seal and the special tool.
3 Install special tool and install the seal.





67. Using the special tool, install the water pump drive pulley.





68. Coat the mating faces of the cylinder heads with sealer.
- Use black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6.





69. Install the left-hand spark plugs.





70. Install the right-hand spark plugs.





71. Install the cylinder head covers.
- Install new gaskets.
- Tighten the bolts in the indicated sequence.





72. Install the fuel charging wiring bracket to the cylinder head cover.





73. Install the right-hand engine lifting eye.





74. Coat the mating faces with sealer.
- Use Black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6.
- Apply a 10 mm diameter dot of sealer onto cylinder block at the indicated areas.

75. NOTE: Note the locations of the studs.

NOTE: Install the oil pan and tighten bolts within six minutes of applying sealer.

NOTE: Install the bolts and studs in the indicated sequence.





Install the oil pan.
- Install a new gasket.





76. Position and install the oil pan heat shields.





77. On SVT equipped vehicles, install the oil cooler.
- Apply Engine oil to the oil cooler gasket, oil cooler insert O-ring seal, and oil filter gasket prior to installation.





78. Install the oil pressure switch.

79. NOTE: If studs were removed, install short end of studs into cylinder head.





Install the left-hand exhaust manifold with the catalytic converter.
- Use a new gasket.
- Tighten the bolts in the indicated sequence.





80. Install the oil filter.





81. Position the right-hand exhaust manifold and install the bolts in the indicated sequence.





82. Install the generator bracket.





83. Install the generator.
1 Install the generator bolts.
2 Install the bracket bolt.





84. Using the special tools, install the crankshaft rear oil seal.
- Lubricate the outer ring and sealing lip with engine oil.

85. NOTE: Use a suitable strap wrench to hold the crankshaft pulley.





Install the flywheel.
1 Install the backing plate.
2 Install the flywheel and tighten the bolts working diagonally.





86. Install the water pump.
1 Position the pump.
2 Install new bolts and tighten them in two stages.
- Stage 1: 10 Nm
- Stage 2: 90 degrees





87. Connect the water pump coolant hoses.
1 Connect the coolant hose to the oil filter adapter.
2 Connect the coolant hose to the cylinder block.





88. Install the coolant crossover tube.
- Use new O-ring seals and lubricate them with coolant.
- Use Premium cooling system fluid.





89. Install the PCV valve and hose.
1 Connect the hose.
2 Install the bracket nut.





90. Install the water pump drive belt.
- Rotate the belt tensioner clockwise to relieve tension on the belt.





91. Install the left-hand engine lifting eye.
1 Position the lifting eye.
2 Install the lifting eye bolt.

92. NOTE: Install the O-ring seal on the dipstick tube prior to installation.





Install the dipstick tube and bolt.
1 Position the dipstick tube using a twisting motion.
2 Install the dipstick tube bolt.





93. Install the coolant distribution tube.





94. Install the thermostat housing with the coolant hoses.

95. NOTE: Install new gaskets with the locating lugs facing downwards.

NOTE: Install the bolts in the indicated sequence.





Install the lower part of the intake manifold.





96. Install the fuel injection system wiring harness.
1 Reconnect the fuel injector electrical connectors beginning at the front of the engine.
2 Reconnect the ECT sensor electrical connector.
3 Reconnect the DPFE sensor electrical connector.





97. Connect the CKP sensor electrical connector.
1 Connect the harness clip.
2 Connect the CKP sensor electrical connector.





98. Connect the CMP sensor electrical connector.
1 Connect the harness clip.
2 Connect the CMP sensor electrical connector.





99. Connect the engine coolant temperature warning light electrical connector.





100. Connect the oil pressure switch electrical connector.





101. Connect the Heated Oxygen Sensor (HO2S) electrical connector.

102. NOTE: Install new gaskets with the locating lugs pointing downwards.

NOTE: Install the bolts in the indicated sequence.





Install the upper part of the intake manifold.





103. Connect the Throttle Position (TP) sensor electrical connector.





104. Connect the PCV hose to the throttle body.





105. Connect the Idle Air Control (IAC) valve electrical connector.





106. Position the vacuum harness and connect the vacuum hoses.
1 Position the vacuum harness and connect the two vacuum supply hoses to the intake manifold.
2 Connect the Electronic Vacuum Regulator (EVR) vacuum hoses.
3 Connect the fuel pressure regulator vacuum hose.
4 Connect the DPFE vacuum hoses.
5 Connect the EGR valve vacuum hoses.





107. Connect the six spark plug wires.





108. Install the ignition coil.
1 Position the coil.
2 Position the capacitor.
3 Position the ground strap.
4 Install the ignition coil bolts.
5 Connect the ignition coil electrical connector.





109. Install the IMRC control unit.
1 Install the IMRC bolts.
2 Connect the IMRC electrical connector.





110. Connect the IMRC cable.
1 Connect the cable to the retainer.
2 Connect the cable end.
111. Position the wiring harness.





112. Connect the (ECT) sensor electrical connector.





113. Connect the EGR Vacuum Regulator (EVR) electrical connector.





114. Connect the DPFE sensor electrical connector.





115. Connect the generator electrical connectors.
1 Install the battery positive voltage lead.
2 Install the voltage regulator electrical connector.
3 Position the stator circuit electrical connector.





116. Install the connecting shaft bracket.