Steps 81-120

Engine

















Engine Upper









Engine Upper - LH Cylinder Head









Engine Upper - RH Cylinder Head









Engine Front









Timing Drive Components - Roller Timing Chain

NOTE: Stamped steel RH timing chain guide shown, composite guide similar.









Timing Drive Components - Inverted Tooth Timing Chain









Lower Engine Block (View 1)









Lower Engine Block (View 2)









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.

NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.

NOTE: Early build engine cylinder heads and fuel injectors differ in design than late build engines. Although these parts are serviced in the same way, the parts are not interchangeable between early build and late build engines. The level of cylinder heads and fuel injectors can be determined by inspecting the engine code label. Early build engines are built through 09/14/2010 (0S 490 BA) and late build engines are built on or after 09/15/2010 (1S 490 BA).

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information Procedures.

81. As a post-check, verify correct alignment of all timing marks.
- There are 38 links between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).

- There are 27 links between the LH intake VCT assembly colored link (2) and the crankshaft sprocket colored link (3).





All engines

82. Inspect the VCT housing seals for damage and replace as necessary.





83. NOTE: RH shown, LH similar.

NOTE: During removal, the O-ring seal may remain on the cylinder head. If so, remove the O-ring seal from the cylinder head, inspect the seal (replace as necessary) and install the O-ring seal on the VCT housing.

Inspect the VCT housing-to-cylinder head O-ring seals for damage and replace as necessary.





84. NOTICE: 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 instruction 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).





85. NOTICE: 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 instruction 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).





86. Install the Alignment Pins.





87. 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 these instructions 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.





88. 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).





89. Remove the Alignment Pins.





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

Install the engine mount bracket and the 3 bolts.





91. 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).





92. 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).





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





94. 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.





95. 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.





96. 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.





97. 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 solenoid seal installation similar.

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





98. 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 these instructions 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.





99. 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).





100. 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 these instructions 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.





101. 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).





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





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





NOTE: Early build engine cylinder heads and fuel injectors differ in design than late build engines. Although these parts are serviced in the same way, the parts are not interchangeable between early build and late build engines. The following illustrations depict early build components, late build components similar.

104. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

Using the Fuel Injector Brush, clean the fuel injector orifices.





105. NOTICE: Do not attempt to cut the lower Teflon(R) seal without first pulling it away from the fuel injector or damage to the injector may occur.

NOTE: Be very careful when removing the lower Teflon(R) seals, not to scratch, nick or gouge the fuel injectors.

Pull the Teflon(R) seal away from the injector with narrow tip pliers.





106. Carefully cut and remove the 6 lower fuel injector Teflon(R) seals.
- Discard the 6 lower fuel injector Teflon(R) seals.





107. NOTE: Do not lubricate the 6 new lower Teflon(R) fuel injector seals.

NOTE: The original lower Teflon(R) fuel injector seals may be either black or white. When installing new seals, always use the black Teflon(R) fuel injector seals.

Install the new Teflon(R) seals on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tips.





108. Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon(R) seals off of the Arbor and into the groove on the fuel injectors.





109. Place the Adjustment Ring (part of the Fuel Injector Seal Installer) beveled side first, over the fuel injector tip until it bottoms out against the fuel injector and turn 180 degrees.
- After one minute, turn the Adjustment Ring back 180 degrees and remove.





110. NOTICE: It is very important to note the routing of the fuel charge wiring harnesses on the fuel rails and index-mark the location of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct fuel charge wire harness routing and tie strap positioning for installation.

Install the fuel charge wire harnesses and tie straps to the index-marked locations on the fuel rails. Start by attaching the first tie strap farthest down the wire harness and continue to the connector end of the harness, leaving ample slack between the fuel injectors.





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

NOTE: To install, apply clean engine oil to the 6 new upper fuel injector O-ring seals only. Do not lubricate the lower fuel injector Teflon(R) seals.

NOTE: Inspect the fuel injector support disks and replace if necessary.

Install the 6 new upper fuel injector O-ring seals.





112. Install the 6 new fuel injector clips.





113. NOTE: RH shown, LH similar.

NOTE: The anti rotation device on the fuel injector has to slip into the groove of the fuel rail cup.

Install the 6 fuel injectors into the fuel rails and connect the 6 electrical connectors.





114. NOTICE: It is very important to visually inspect the routing of the wire harness to make sure that the wire harness will not be pinched or damaged between the fuel rail and the cylinder head during installation.

Install the 6 bolts and the RH fuel rail assembly.

- Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and then proceed inward.

- To install, tighten to 10 Nm (89 lb-in).

- Tighten an additional 45 degrees.





115. NOTICE: It is very important to visually inspect the routing of the wire harness to make sure that the wire harness will not be pinched and damaged between the fuel rail and the cylinder head during installation.

Install the 6 bolts and the LH fuel rail assembly.

- Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and proceed inward.

- To install, tighten to 10 Nm (89 lb-in).

- Tighten an additional 45 degrees.





116. 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.





117. 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.





118. 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.





119. 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.





120. 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.