Part 4
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
Timing Drive Components
Engine Lower (View 1)
Lower Engine Block (View 2)
NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can 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.
84. Install the engine mount bracket and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
85. 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.
86. 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.
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 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.
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 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.
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).
93. Install the wiring harness retaining bracket and the 2 nuts.
- Tighten to 4 Nm (35 lb-in).
94. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.
- Tighten to 7 Nm (62 lb-in).
95. Using a new gasket, install the oil filter adapter and 3 bolts.
- Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.
96. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP (Engine Oil Pressure) switch.
- Tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.
97. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
98. Install LH Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
99. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
100. 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).
101. Using a new gasket, install the thermostat housing and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
102. 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.
103. 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
104. Install the catalytic converter bracket and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).
All engines
105. Install the RH CMP (Camshaft Position) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
106. Install the engine lifting eye and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
107. Install the cover and the pin-type retainer.
108. Install the LH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
109. Install the RH cylinder block drain plug or, if equipped, the block heater.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
- Tighten the block heater to 40 Nm (30 lb-ft).
