Part 2

Engine

Special Tool(s)








Material








Engine Upper

Engine Upper:

Engine Front

Engine Front:

Engine Lower

Engine Lower:

LH Cylinder Head

LH Cylinder Head:

RH Cylinder Head

RH Cylinder Head:

47. As a post-check, verify correct alignment of all timing marks.





48. Install new VCT housing seals.





49. CAUTION: Make sure the dowels on the variable camshaft timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.

Install the LH VCT housing and the 3 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





50. CAUTION: Make sure the dowels on the variable camshaft timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.

Install the RH VCT housing and the 3 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





51. Install the special tools.





52. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
^ Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.





53. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and bolts 17, 18, 19 and 20.
^ Tighten in sequence to 3 Nm (27 lb-in).





54. Remove the special tools (alignment pins).

55. NOTE: Do not tighten the bolts at this time.

Install the engine mount bracket and the 3 bolts.





56. CAUTION: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
^ Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft).
^ Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).





57. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 lb-ft).





58. Install the engine mount bracket and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).





59. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Using the special tools, install a new crankshaft front seal.





60. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using he special tools, install the crankshaft pulley.





61. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.





62. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

NOTE: Spark plug tube seal installation shown, VCT seal installation similar.

Using the special tools, install new VCT solenoid and/or spark plug tube seals.





63. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened 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. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.





64. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





65. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened 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. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.





66. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





67. NOTE: LH shown, RH similar.

Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 7 Nm (62 lb-in).





68. Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts.
^ Tighten the large bolt to 57 Nm (42 lb-ft).
^ Tighten the small bolt to 10 Nm (89 lb-in).





69. NOTE: Apply thread sealant with PTFE to the engine oil pressure (EOP) switch threads.

Install the EOP switch.
^ Tighten to 18 Nm (13 lb-ft).





70. Install the crankshaft position (CKP) sensor and install the bolt.
^ Tighten to 10 Nm (89 lb-in).





71. Install LH camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).





72. Install and connect the CHT sensor jumper harness.






73. Using new gaskets, install the lower intake manifold and the 10 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





74. Using a new gasket, install the thermostat housing and the 3 bolts.
^ Tighten to 10 Nm (89 lb-in).





75. CAUTION: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: The upper and lower O-ring seals are not interchangeable.

Install new fuel injector O-ring seals.
^ Remove the retaining clips and separate the fuel injectors from the fuel rail.
^ Remove and discard the O-ring seals.
^ Install new O-ring seals and lubricate with clean engine oil.
^ Install the fuel injectors and the retaining clips onto the fuel rail.





76. Install the fuel rail and injectors as an assembly and install the 4 bolts.
^ Tighten to 10 Nm (89 lb-in).





77. Install the coolant bypass hose to the thermostat housing.





78. Install the RH CMP sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).





79. NOTE: Align the bracket with the index mark made during removal.

Install the upper intake manifold short support bracket and the bolt.
^ Tighten to 10 Nm (89 lb-in).





80. NOTE: Align the bracket with the index mark made during removal.

If equipped, install the upper intake long support manifold bracket and the bolt.
^ Tighten to 10 Nm (89 lb-in).





81. Install the engine lifting eye and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).





82. Install the cover and the pin-type retainer.





83. Install the LH cylinder block drain plug.
^ Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.





84. Install the RH cylinder block drain plug or, if equipped, the block heater.
^ Tighten to 40 Nm (30 lb-ft).





85. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).





86. CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten to 20 Nm (15 lb-ft).





87. Install the RH exhaust manifold heat shield and the 3 bolts.
^ Tighten to 14 Nm (10 lb-ft).





Front wheel drive (FWD) vehicles
88. Install the 4 new RH catalytic converter-to-exhaust manifold studs.
^ Tighten to 25 Nm (18 lb-ft).





89. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
^ Tighten to 40 Nm (30 lb-ft).





All vehicles
90. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).





91. CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten to 20 Nm (15 lb-ft).





92. Install the LH exhaust manifold heat shield and the 3 bolts.
^ Tighten to 14 Nm (10 lb-ft).





93. Install the 4 new LH catalytic converter-to-exhaust manifold studs.
^ Tighten to 25 Nm (18 lb-ft).





94. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
^ Tighten to 40 Nm (30 lb-ft).





95. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 10 Nm (89 lb-in).