Part 4

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

70. Reset the primary timing chain tensioner.
1. Release the ratchet detent.

2. Using a soft-jawed vise, compress the ratchet plunger.

3. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a suitable lockpin.






71. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
Install the primary tensioner and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).

- Remove the lockpin.






72. As a post-check, verify correct alignment of all timing marks.
- There are 48 links between the RH intake VCT (Variable Camshaft Timing) assembly colored link (1) and the LH intake VCT (Variable Camshaft Timing) assembly colored link (2).

- There are 35 links between the LH intake VCT (Variable Camshaft Timing) assembly colored link (2) and the 2 crankshaft sprockets colored links (3).






73. Inspect the VCT (Variable Camshaft Timing) housing seals for damage and replace as necessary.





74. 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 (Variable Camshaft Timing) housing.
Inspect the VCT (Variable Camshaft Timing) housing-to-cylinder head O-ring seals for damage and replace as necessary.






75. 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 process will result in severe engine damage.

Install the LH VCT (Variable Camshaft Timing) housing and the 3 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






76. 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 process will result in severe engine damage.

Install the RH VCT (Variable Camshaft Timing) housing and the 3 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






77. Install the Alignment Pins.





78. 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 this procedure 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.






79. 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).






80. Remove the Alignment Pins.





81. NOTE: Do not tighten the bolts at this time.
Install the engine mount bracket and the 3 bolts.






82. 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).






83. 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).






84. Install the engine mount bracket and the 2 bolts.
- Tighten to 30 Nm (22 lb-ft).






85. 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.






86. 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.






87. 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.






88. 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 (Variable Camshaft Timing) solenoid seal installation similar.

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





89. 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-RH cylinder head joints.






90. Using a new gasket, install the RH valve cover and tighten the bolt and 8 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






91. 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.






92. 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).