Part 3

Engine - Assembly - (Con't)





61. Remove the retaining clip from the LH timing chain tensioner.





62. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.





63. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.





64. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.





65. Remove the retaining clip from the RH timing chain tensioner.





66. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.





67. Make sure that the camshaft sprocket keyways are 90° from the valve cover mounting surface.





68. Remove special tools from the camshaft.

All engines





69. Install the crankshaft sensor ring on the crankshaft.





70. NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant along the head-to-block surface and the oil pan-to-block surface as specified.





71. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.

4.6L - Engine Front Cover Sequence:

Romeo engine (4.6L)








72. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).

5.4L - Engine Front Cover Bolt Sequence:

Windsor engine (5.4L)








73. Tighten the engine front cover fasteners in sequence in three stages.
^ Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.).
^ Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 ft. lbs.).

All engines





74. Install the oil pump screen and pickup tube spacer.





75. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-ring with clean engine oil.

Position the oil pump screen and pickup tube and install the bolts.





76. NOTE: Clean and inspect the mating surfaces, and install new gaskets.

Position the oil filter adapter and install the rear nut.





77. Install the four front bolts.





78. Position the engine mounts to the cylinder block and install the six bolts.





79. Position the belt idler pulley and install the bolt.





80. CAUTION: Do not rotate the water pump housing once the water pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Install the water pump.
1 Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the water pump.
2 Position the water pump into the engine block.
3 Install the bolts.





81. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.





82. Use the special tool to install the crankshaft front oil seal into the engine front cover.





83. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





84. Use the special tool to install the crankshaft pulley.





85. Tighten the crankshaft pulley bolt in four stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360°.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 85 - 95°.





86. Position the water pump pulley on the water pump and install the bolts.





87. NOTE: The front lower hole in the power steering pump is not used.

Position the power steering pump and install the bolts.





88. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.





89. Position the LH valve cover and the valve cover gasket on the cylinder head and install the bolts loosely.

Romeo engine (4.6L)





90. Tighten the bolts in the sequence shown.