Steps 51-100
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.
51. Install the Alignment Pins.
52. NOTICE: Failure to use Motorcraft 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 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 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.
53. 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).
54. Remove the Alignment Pins.
55. NOTE: Do not tighten the bolts at this time.
Install the engine mount bracket and the 3 bolts.
56. NOTICE: Do not expose the Motorcraft 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).
57. NOTICE: The Threadlock and Sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new thread 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 Threadlock and 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).
58. Install the engine mount bracket and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
59. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
60. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the crankshaft pulley.
61. 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.
62. 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.
63. NOTICE: Failure to use Motorcraft 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 High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
64. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
65. NOTICE: Failure to use Motorcraft 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 High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
66. Using a new gasket, install the LH valve cover and 11 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
67. Install the wiring harness retaining bracket and the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
68. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.
- Tighten to 7 Nm (62 lb-in).
69. Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts.
- Tighten the large bolt to 57 Nm (42 lb-ft).
- Tighten the small bolt to 10 Nm (89 lb-in).
70. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP switch.
- Tighten to 18 Nm (159 lb-in).
71. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
72. Install LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
73. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
74. 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.
Using new gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
75. Using a new gasket, install the thermostat housing and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
76. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: The upper and lower O-ring seals are not interchangeable.
Install new fuel injector O-ring seals.
- Remove the retaining clips and separate the fuel injectors from the fuel rail.
- Remove and discard the O-ring seals.
- Install new O-ring seals and lubricate with clean engine oil.
- Install the fuel injectors and the retaining clips onto the fuel rail.
77. Install the fuel rail and injectors as an assembly and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
All-Wheel Drive (AWD) vehicles
78. Install the catalytic converter bracket and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).
All vehicles
79. Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
80. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
81. Install the cover and the pin-type retainer.
82. Install the LH cylinder block drain plug.
- Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
83. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten to 40 Nm (30 lb-ft).
84. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
85. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
Front Wheel Drive (FWD) vehicles
86. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).
All vehicles
87. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
88. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
89. Install the LH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
90. Using a new gasket, install the LH catalytic converter and the 4 new nuts (3 shown).
- Tighten to 40 Nm (30 lb-ft).
91. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
92. Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
93. Install the Power Steering Pressure (PSP) tube bracket and bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).
94. Install the PSP hose bracket nut.
- Tighten to 9 Nm (80 lb-in).
95. Attach the PSP hose retainer to the engine lifting eye.
96. Install the generator, the nut and the bolt.
- Tighten to 48 Nm (35 lb-ft).
97. Using new O-ring seals, install the A/C manifold and the bolt.
- Tighten to 25 Nm (18 lb-ft).
98. Position the wiring harness onto the engine.
99. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
100. Attach the wiring harness retainer to the generator.
