Part 2

Engine














Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










Timing Drive Components










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.

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.

All engines

24. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.

25. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in 2 steps.
- Stage 1: Tighten fasteners to 24 Nm (18 lb-ft).

- Stage 2: Tighten fasteners an additional 180 degrees.






26. 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 crankshaft rear seal retainer must be installed and the bolts tightened within 4 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 crankshaft rear seal retainer.






27. Install the crankshaft rear seal retainer and the 8 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






28. Install the oil pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).






29. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






30. NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.
Install the A/C compressor and the 2 bolts.

- Tighten to 25 Nm (18 lb-ft).






31. 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.






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

- Loosen the bolts 180 degrees.






33. 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.






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





35. 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).






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






37. Install the coolant pump and the 8 bolts. Tighten in the sequence shown in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.






38. Install the Knock Sensor (KS) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).






39. NOTE: Apply clean engine coolant to the O-ring seals prior to installation.
Using new O-ring seals, install the coolant inlet tube.






40. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 35 Nm (26 lb-ft).

- Stage 3: Tighten 90 degrees.

- Stage 4: Tighten 90 degrees.

- Stage 5: Tighten 45 degrees.






41. Install the M6 bolt.
- Tighten to 10 Nm (89 lb-in).






42. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 35 Nm (26 lb-ft).

- Stage 3: Tighten 90 degrees.

- Stage 4: Tighten 90 degrees.

- Stage 5: Tighten 45 degrees.






43. Install the M6 bolt.
- Tighten to 10 Nm (89 lb-in).






44. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

Position the crankshaft dowel pin in the 9 o'clock position.






45. NOTE: The valve tappets must be installed in their original positions.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

NOTE: LH shown, RH similar.
Install the valve tappets.






46. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH cylinder head in the neutral position as shown.