Steps 66-129

NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.

NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure.

66. Using the special tool, install the crankshaft pulley.

67. CAUTION: A new bolt must be used each time it is removed.

Tighten the bolt in two steps.
- Step 1: Tighten to 45 Nm.
- Step 2: Rotate an additional 90°.

68. NOTE: The camshaft sprocket must turn freely on camshaft. DO NOT tighten the bolt.

Install the RH rear camshaft bolt.

69. Install the bolt.

70. NOTE: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install the LH front camshaft bolt.

71. Install the bolt.

72. Turn the crankshaft one revolution.

73. NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).

Install the special tool.

74. NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the front of the RH cylinder head.

75. NOTE: Leave the top two special tool clamp bolts loose.

Install the special tools on the rear of the RH cylinder head.

76. Install the special tool.

77. CAUTION: The right-hand camshaft sprocket bolt is a left-handed threaded bolt.

Tighten the bolts.
1 Tighten the special tool top two clamp bolts to 10Nm (89 lb-in.).
2 Tighten the camshaft bolt.

78. Remove the special tool and install the RH camshaft tensioner.
- If using a new washer, tighten to 44 Nm (32 lb-ft.).
- If using the old washer, tighten to 67 Nm (47 lb-ft.).

79. Remove the special tools from the RH cylinder head.

80. NOTE: Do not tighten the special tool top two clamp bolts. Camshaft sprocket must rotate freely.

Install the special tools on the front of the LH cylinder head.

81. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the rear of the LH cylinder head.

82. Install the special tool.

83. Tighten the bolts.
1. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in.)
2. Tighten the camshaft bolt.

84. Remove the special tool and install the RH camshaft tensioner.
- If using a new washer, tighten to 44 Nm (32 lb-ft.).
- If using the old washer, tighten to 67 Nm (47 lb-ft.).

85. Remove the special tools from the LH cylinder head.

86. Remove the special tool.

87. NOTE: Lubricate the parts with clean engine oil prior to installing.

Using the special tool, install the roller followers in their original position.

88. Install the gasket and the LH exhaust manifold.

89. Install the gasket and the RH exhaust manifold.

90. NOTE: Prior to installation, use Metal Surface Cleaner F4AZ-19AS36-RA or equivalent meeting Ford specification WSE-MSB392-A to clean mating surfaces.

Install the knock sensor.

91. Install the oil level indicator tube.

92. NOTE: If the oil level indicator tube is not installed flush with the cylinder block, false readings of the oil level may occur.

Make sure the oil level indicator tube is flush with the cylinder block.

93. Install the crankcase vent separator.

94. Install the thermostat housing.

- Inspect and install a new gasket if necessary.

95. Connect the water bypass hose.

96. Install the VMV hose bracket.

97. Install the fuel injectors.
- Lubricate the fuel injector O-ring with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

98. Install the gasket and RH valve cover.

99. Install the bracket and the transmission fill tube.

100. Install the gasket and the LH valve cover.

101. Install the fuel injection supply manifold.

102. Install the lower fuel line bracket.

103. Connect the EGR valve to exhaust manifold tube to the exhaust manifold.

104. Connect the EGR valve to exhaust manifold tube to the EGR valve.

105. Install the fuel charging wiring.

106. NOTE: LH side shown; RH side similar.

Connect the six fuel injector electrical connectors.

107. Connect the water temperature indicator sender unit and the Engine Coolant Temperature (ECT) sensor electrical connectors.

108. Connect the knock sensor (KS) electrical connector.

109. Install the lower intake manifold.

110. Connect the LH VMV hose.

111. Connect the RH VMV hose.

112. Install the upper intake manifold.

- Inspect and install a new gasket if necessary.

113. Connect the crankcase ventilation hose.

114. Connect the RH upper intake manifold vacuum hose.

115. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.

NOTE: Apply silicone brake caliper and dielectric compound to the inside of the spark plug boots.

Install the spark plug wires to the spark plugs.