Part 4
Engine
a Early build vehicle cooling systems are filled with Motorcraft(R) Specialty Green Engine Coolant and late build vehicle cooling systems are filled with Motorcraft(R) Specialty Orange Engine Coolant. Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.
Lower Engine Block (View 1)
Lower Engine Block (View 2)
Front Engine Block
Cylinder Head
Intake Manifold
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools or severe engine damage can occur.
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.
85. Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).
86. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
Clean the valve cover gasket surface with metal surface prep.
87. Apply silicone gasket and sealant to the locations shown.
88. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
Install the valve cover.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
89. NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.
Install the oil level indicator.
90. Install the Cylinder Head Temperature (CHT) sensor.
- Tighten to 12 Nm (106 lb-in).
91. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
Install the 4 coil-on-plugs and the 4 bolts. Install the crankshaft vent tube.
- Tighten to 8 Nm (71 lb-in).
92. Install the engine cover studs (one shown).
93. Install the crankshaft vent tube.
94. If equipped, install the block heater.
- Tighten to 40 Nm (30 lb-ft).
95. NOTE: Clean the gasket mating surfaces with metal surface prep.
Install the oil filter adapter with a new gasket.
- Tighten to 25 Nm (18 lb-ft).
96. Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).
97. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
Install the KS (Knock Sensor) and the bolt.
- Tighten to 20 Nm (177 lb-in).
98. Install the coolant hose.
99. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
Install the thermostat housing.
- Tighten to 10 Nm (89 lb-in).
100. NOTICE: Make sure the coolant pump is correctly seated to the engine block before installing and tightening the fasteners, or damage to the coolant pump may occur.
NOTE: Clean the coolant pump mating surface with metal surface cleaner.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
Install the new O-ring, coolant pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
101. Install the coolant pump pulley and bolts.
- Tighten to 20 Nm (177 lb-in).
102. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
Install new fuel injector O-rings.
- Separate the fuel injectors from the fuel rail.
- Remove and discard the fuel injector O-rings.
- Install new O-rings and lubricate with clean engine oil.
- Install the fuel injectors onto the fuel rail.
103. Install the fuel rail with the fuel injectors and stud bolts.
- Tighten to 23 Nm (17 lb-ft).
104. Install the radio capacitor and the nut.
- Tighten to 10 Nm (89 lb-in).
105. Install the fuel rail insulator.
106. Attach the 2 wiring harness retainers to the valve cover and stud bolt.
- Connect the EGR valve electrical connector.
107. Connect the CHT (Cylinder Head Temperature) sensor and install the rubber boot.
108. Connect the 4 coil-on-plug electrical connectors.
109. Connect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
110. Install the EGR tube.
- Tighten to 55 Nm (41 lb-ft).
111. Position the intake manifold and connect the PCV hose.
112. 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.
NOTE: Inspect and install new intake manifold gaskets, if necessary.
NOTE: The cylinder head side of the intake manifold is showing bolt location.
Install the intake manifold gasket, intake manifold and 7 bolts.
- Tighten to 18 Nm (159 lb-in).
113. Attach the 3 wire harness pin-type retainers to the intake manifold.
