Part 3
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
NOTE: Early build shown, late build similar.
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: Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.
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.
NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.
Early build vehicles
90. 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).
Late build vehicles
91. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
All vehicles
92. 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.
Early build vehicles
93. Using a new gasket, install the LH valve cover and 11 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
Late build vehicles
94. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
All vehicles
95. Install the engine cover stud to the LH valve cover stud bolt.
- Tighten to 6 Nm (53 lb-in).
96. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.
- Tighten to 7 Nm (62 lb-in).
97. 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).
98. Using a new gasket, install the oil filter adapter and 3 bolts.
- Tighten to 10 Nm (89 lb-in).
99. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
100. Install LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
101. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
102. 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).
103. Using a new gasket, install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
104. 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.
105. Install the fuel rail and injectors as an assembly and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
106. Install the coolant bypass hose to the thermostat housing.
107. Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
108. NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold support bracket and the bolt.
- Tighten to 10 Nm (89 lb-in).
109. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
110. Install the cover and the pin-type retainer.
111. Install the LH cylinder block drain plug.
- Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
112. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten to 40 Nm (30 lb-ft).
113. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
114. 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).
115. Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
