Installation
1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47.
2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48.
3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft).
4. Install power steering bracket to left cylinder head.
5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in).
6. Install right cylinder head gasket.
7. Install right cylinder head.
8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages:
^ Stage 1: 37-43 Nm (27-32 lb-ft).
^ Stage 2: Rotate 85-95 degrees.
^ Stage 3: Rotate 85-95 degrees.
9. Lubricate all camshaft journals.
10. Install left cylinder head gasket.
11. Install left cylinder head.
12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages:
^ Stage 1: 37-43 Nm (27-32 lb-ft).
^ Stage 2: Rotate 85-95 degrees.
^ Stage 3: Rotate 85-95 degrees.
13. Lubricate all camshaft journals.
14. Raise vehicle.
15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft).
16. Install right side exhaust manifold gasket.
NOTE:
Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head.
17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft).
18. Position engine oil indicator tube in installed position.
19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft).
20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in).
21. Replace oil filter.
22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft).
23. Lower vehicle.
24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in).
25. On 4X4 models, install one screw removed from both wheel opening moldings.
26. On Romeo engines, proceed as follows:
^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53.
^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53.
27. On 4.6L and 5.4L Windsor engines, proceed as follows:
^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53.
^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53.
^ Install Camshaft Holding Tool T96T-6256-B on each camshaft.
28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft).
CAUTION
Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur.
29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position.
30. Remove Crankshaft Holding Tool.
31. Compress timing chain tensioner plunger as follows:
CAUTION
Do not compress the ratchet assembly. This will damage the ratchet assembly.
CAUTION
Use protective vocers over jaws of vise to prevent damage to tensioner.
^ Compress tensioner plunger using edge of vise. See Figure 55.
^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56.
^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57.
^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58.
^ Remove tensioner from vise.
^ Repeat procedure for second tensioner.
32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary.
33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in).
34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in).
35. Install timing chains and sprockets as follows:
^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket.
^ Slide left side sprocket and chain on crankshaft.
^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned.
^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket.
^ Slide right side sprocket and chain on crankshaft.
^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned.
^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60.
^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61.
36. Install right and left timing chain tensioner guides.
37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft).
38. Remove paper clips from both timing chain tensioners.
39. Remove both camshaft holding tools.
40. Install crankshaft sensor ring.
41. Install engine front cover as follows:
NOTE:
The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62.
^ Using new gasket, install engine front cover. Align cover with cylinder block dowel.
^ Loosely install engine front cover bolts and stud bolts.
^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft).
^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft).
42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft).
43. Using clean engine oil, lubricate engine front cover oil seal inner lip.
44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal.
45. Install crankshaft pulley as follows:
NOTE:
The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65.
^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley.
^ Loosely install crankshaft pulley bolt.
^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft).
^ Loosen crankshaft pulley bolt one (1) full turn.
^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft).
^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn).
46. On Romeo engines, proceed as follows:
^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft).
^ Raise vehicle.
^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft).
47. On 4.6L and 5.4L Windsor engines, proceed as follows:
^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft).
^ Raise vehicle.
^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft).
48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages:
^ Stage 1: 20 Nm (15 lb-ft).
^ Stage 2: Rotate an additional 60 degrees.
49. Lower vehicle.
50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump.
51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft).
52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft).
53. Install radiator. Make sure radiator is sitting on mounting insulators.
54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft).
55. Connect lower radiator hose to radiator.
56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft).
57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in).
58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly.
59. Connect coolant recovery hose to radiator.
60. Install air deflector on top of radiator.
61. Install jack handle on radiator air deflector.
62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft).
NOTE:
Make sure left side fuel charge harness is between routing bracket and cylinder head.
63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in).
64. Install heater return hose to coolant tube.
65. Install cam cover gaskets on both cam covers.
NOTE:
The cam cover must be installed within four (4) minutes after applying silicone.
66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head.
67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in).
NOTE:
The cam cover must be installed within four (4) minutes after applying silicone.
68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head.
69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in).
70. Install new intake manifold gaskets.
71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages:
^ Stage 1: 2 Nm (18 lb-in).
^ Stage 2: 20-30 Nm (15-22 lb-ft).
72. Loosely position left side fuel charge harness on cam cover.
73. Connect tuning valve electrical connector.
74. Connect CHT sensor electrical connector.
75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in).
76. Install drive belt.
77. Using tie strap, retain alternator wiring harness to fuel manifold.
78. On 4.6L engines, proceed as follows:
^ Loosely position right side fuel charge harness on cam cover.
^ Connect water temperature sensor electrical connector.
^ Connect ECT sensor electrical connector.
^ Connect right side ignition wires to spark plugs.
^ Clip ignition wire separators to right cam cover.
^ Connect right side fuel injector electrical connectors.
^ Clip right side fuel charge harness to cam cover.
^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft).
^ Connect ignition wires to right side coil.
^ Connect right side radio interference suppressor electrical connector.
^ Connect right side coil pack electrical connector.
79. On 5.4L engines, proceed as follows:
^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in).
^ Position right side fuel charge harness on cam cover studs.
^ Connect right side fuel injector electrical connectors.
^ Connect right side ignition coil electrical connectors.
^ Connect right side radio interference suppressor.
80. Install PCV valve and line assembly.
81. Connect ground strap to bulkhead.
82. Connect heater return hose to heater core.
83. Install heater supply hose.
84. Install junction block bracket. Tighten retainers securely.
85. Connect single-pin electrical connector.
86. Connect 16-pin electrical connector.
87. Install both 42-pin bulkhead electrical connector halves to junction block bracket.
88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in).
89. Clip two (2) mega-fuses to junction block bracket.
90. Connect positive leads to starter relay.
91. Install junction block bracket splash shield.
92. Connect fuel lines to fuel manifold.
93. On 4.6L engines, proceed as follows:
^ Connect left side ignition wires to spark plugs.
^ Clip ignition wire separators to left cam cover.
^ Connect left side fuel injector electrical connectors.
^ Clip left side fuel charge harness to cam cover.
^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft).
^ Connect ignition wires to left side coil.
^ Connect left side radio interference suppressor electrical connector.
^ Connect CMP electrical connector.
^ Connect left side coil pack electrical connector.
^ Connect DPFE transducer electrical connector.
^ Connect IAC motor electrical connector.
^ Connect TP sensor electrical connector.
^ Connect EVR solenoid electrical connector.
^ Connect crankcase vent tube to left cam cover.
^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft).
94. On 5.4L engines, proceed as follows:
^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in).
^ Connect left side fuel injector electrical connectors.
^ Connect left side ignition coil electrical connectors.
^ Connect ECT sensor electrical connector.
^ Connect TP sensor electrical connector.
^ Connect EVR solenoid electrical connector.
^ Connect DPFE transducer electrical connector.
^ Connect left side radio interference suppressor electrical connector.
^ Connect IAC motor electrical connector.
^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold.
^ Connect VMV purge line to top of throttle body adapter.
^ Position vacuum harness on top of motor.
^ Connect vacuum tap to right side of throttle body adapter.
^ Connect EVR solenoid vacuum line.
^ Connect EGR valve vacuum line.
^ Connect fuel pressure regulator vacuum line.
^ Connect vapor management valve vacuum line.
95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time.
96. Connect DPFE transducer hoses to EGR tube.
97. On 4X4 models, connect A/C clutch electrical connector.
98. Raise vehicle.
99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft).
100. On 4X2 models, connect A/C clutch electrical connector.
101. Connect CKP sensor electrical connector.
102. Connect oil pressure switch electrical connector.
103. Lower vehicle.
104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft).
105. On 4.6L engines, proceed as follows:
^ Loosely position vacuum harness over engine.
^ Connect EVR solenoid vacuum line.
^ Connect EGR valve vacuum line.
^ Connect fuel pressure regulator vacuum line.
^ Connect vapor management valve vacuum line.
^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in).
^ Connect vacuum tap on right side of throttle body adapter.
^ Connect VMV vacuum line at rear of throttle body adapter.
106. On 5.4L engines, proceed as follows:
^ Connect crankcase vent tube to left cam cover.
^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft).
107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir.
108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in).
109. Connect accelerator cable, speed control cable and return spring to throttle body.
110. Connect upper radiator hose to thermostat housing.
111. Install rear half of air cleaner.
112. Install front half of air cleaner and clean air lube.
113. Connect IAT and MAF electrical connectors.
114. Install throttle body shield.
115. Connect battery negative cable.
116. Remove memory saver.
117. Fill engine with new engine oil.
118. Fill cooling system as follows:
^ Add 50/50 coolant mixture to radiator coolant recovery reservoir.
^ Install radiator cap.
^ Move temperature blend selector to full warm position.
^ Run engine until it reaches operating temperature.
^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks.
^ Turn off engine and allow cooling system to cool.
^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool.
119. On air suspension equipped models, turn air suspension switch to ON position.
120. Check engine for proper operation.