Steps 1-40

Oil Pan













NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. NOTICE: Failure to use Motorcraft(R) High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

Apply a 3 mm (0.11 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the sealing surface of the oil pan.

- Apply a 5.5 mm (0.21 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.





2. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

Install the oil pan and bolts 10, 11, 13 and 14.

- Tighten in the sequence shown to 3 Nm (27 lb-in).

- Loosen the bolts 180 degrees.





3. Align the oil pan to the cylinder block and A/C compressor.
- Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.





4. Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).





5. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown.
- Tighten the large bolts (1-14) to 20 Nm (177 lb-in).

- Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).





6. Install the A/C compressor mounting stud, bracket and nut.
- Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).





7. Install the Alignment Pins.





8. NOTICE: Failure to use Motorcraft(R) 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(R) 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(R) 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.





9. 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 shown to 3 Nm (27 lb-in).





10. Remove the Alignment Pins.





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

Install the engine mount bracket and the 3 bolts.





12. NOTICE: Do not expose the Motorcraft(R) 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 (133 lb-in).

- 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).





13. NOTICE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.

Install the engine mount studs in the following sequence.

1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.

2. Clean all the thread sealer from the engine mount studs (old and new studs).

3. Apply new Threadlock and Sealer to the engine mount stud threads.

4. Install the 2 engine mount studs.
- Tighten to 20 Nm (177 lb-in).





14. Install the stud bolt and Heated Oxygen Sensor (HO2S) connector bracket to the engine front cover.
- Tighten to 10 Nm (89 lb-in).





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

Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.





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

Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.





17. Using the Strap Wrench, 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.





18. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).





19. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.





20. 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, Variable Camshaft Timing (VCT) solenoid seal installation similar.

Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.





21. NOTICE: Failure to use Motorcraft(R) 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(R) High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.





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





23. NOTICE: Failure to use Motorcraft(R) 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(R) High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.





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





25. Install the 3 RH ignition coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).





26. Install the 3 LH ignition coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).





27. NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.

Using the crankshaft pulley bolt, turn the crankshaft until the fuel injection pump cam lobe is at BDC.





28. NOTE: Valve cover is removed for clarity.

NOTE: Apply clean engine oil to the fuel injection pump mounting pedestal bore.

Install the fuel injection pump roller tappet.





29. NOTE: Apply clean engine oil to the fuel injection pump mounting plate seal.

Inspect the fuel injection pump mounting plate-to-valve cover gasket and replace if necessary.





30. NOTE: Apply clean engine oil to the fuel injection pump mounting plate O-ring seals.

Inspect the 2 fuel injection pump mounting plate O-ring seals and replace if necessary.





31. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.

Install the fuel injection pump on the fuel injection pump mounting plate.





32. NOTE: Apply clean engine oil to the fuel injection pump mounting plate O-ring seals.

Inspect the 2 fuel injection pump mounting plate O-ring seals and replace if necessary.





33. NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.

Install the fuel injection pump on the fuel injection pump mounting plate.





34. NOTE: Clean the fuel injection pump bolts and apply Thread Sealant with PTFE to the bolts.

Install the fuel injection pump and the 2 bolts finger-tight.

- Tighten to 10 Nm (89 lb-in).

- Tighten an additional 45 degrees.





35. NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.

Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.

- Stage 1: Tighten to 32 Nm (24 lb-ft).

- Stage 2: Wait 10 minutes to minimize pre-stress.

- Stage 3: Tighten to 32 Nm (24 lb-ft).





36. Install the high-pressure fuel tube bracket nut.
- Tighten to 8 Nm (71 lb-in).





37. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

38. Connect the 3 RH ignition coil-on-plug electrical connectors.





39. Connect the RH VCT solenoid electrical connector and attach the 2 wiring harness retainers.





40. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Make sure the fuel rail wiring harnesses are routed correctly.

NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.

Using new intake manifold, coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).