Steps 101-139

Engine













Engine Upper









Engine Front









Engine Lower









LH Cylinder Head









RH Cylinder Head









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: Early build vehicle (built before May 18, 2009) cooling systems are filled with Motorcraft(R) Premium Gold Engine Coolant. Late build vehicle (built on or after May 18, 2009) cooling systems are filled with Motorcraft(R) Specialty Green Engine Coolant. Mixing coolant types degrades the corrosion protection of the coolant. Do not mix coolant types. Failure to follow these instructions may result in engine or cooling system damage.

101. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.





102. Connect the generator electrical connector.





103. Connect the generator B+ cable and install the nut.
- Tighten to 6 Nm (53 lb-in).





104. Connect the A/C compressor electrical connector.
- Attach the A/C compressor wiring harness retainer.





105. Connect the CKP sensor electrical connector.





106. Install the wiring harness grommet.





107. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).





108. Install the heat shield, the nut and the bolt.
- Tighten to 10 Nm (89 lb-in).





109. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

110. Connect the LH camshaft VCT solenoid electrical connector.





111. Connect the 3 LH coil-on-plug electrical connectors.





112. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.





113. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.





114. Connect the LH CMP sensor electrical connector.





115. Connect the CHT sensor electrical connector.





116. Connect the 6 fuel injector electrical connectors (3 shown).





117. Install the RH cylinder head ground cable and the bolt.
- Tighten to 10 Nm (89 lb-in).





118. Connect the KS electrical connector.





119. Connect the RH CMP sensor electrical connector.





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

121. Connect the 3 RH coil-on-plug electrical connectors.





122. Connect the RH VCT solenoid electrical connector.





123. Connect the RH HO2S electrical connector.





FWD vehicles

124. Connect the RH CMS electrical connector.





All vehicles

125. Connect the PSP switch electrical connector.





126. Using a new gasket, install the upper intake manifold and the 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





127. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer.
- Tighten to 6 Nm (53 lb-in).





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





129. Attach the 4 wiring harness retainers to the upper intake manifold.





130. Connect the Throttle Body (TB) electrical connector.





131. Connect the PCV hose to the PCV valve.





132. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.

133. If equipped, connect the block heater electrical connector and install the heat shield.





134. Install the Engine Lift Eye on the LH cylinder head.





135. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.





136. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.





137. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





138. Install the crankshaft sensor ring.





139. Install the flexplate and the 8 bolts.
- Tighten to 80 Nm (59 lb-ft).