Part 2 of 2
56. Install the remaining engine front cover bolts and studs and tighten in the indicated sequence.
NOTE: Lubricate the new O-rings with light engine oil before installation.
57. install the following sensors and wiring brackets.
- Install the CKP sensor and bolt.
- Install the CMP sensor and bolt.
NOTE: Lubricate the outer ring and sealing lip with engine oil.
58. Use a Front Crankshaft Seal Replacer and a Crankshaft Damper Replacer and install the crankshaft front oil seal.
1 Install front crankshaft seal replacer.
2 Install crankshaft damper replacer and install the seal.
NOTE: Prior to applying sealer, clean sealing surfaces with metal surface cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealers ability to adhere.
59. Apply black silicone rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A6 to the front of the crankshaft on the inside diameter surface of the crankshaft pulley at keyway.
NOTE: Use the crankshaft pulley bolt washer for installation.
60. Use the Crankshaft Damper Replacer and install the crankshaft pulley.
1 Position the pulley.
2 Install the damper replacer and install the pulley.
61. Install the crankshaft pulley
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 and seal the keyway in the pulley.
- Use the a suitable strap wrench to hold the crankshaft pulley.
- Tighten the crankshaft pulley bolt in four stages.
- Stage 1: 120 Nm
- Stage 2: Back off bolt one full turn
- Stage 3: 50 Nm
- Stage 4: 90°.
62. Install the power steering pump and bracket.
- Loosely install all bolts and studs.
NOTE: The longer 84mm bolts should be torqued first.
63. Tighten the power steering pump bolts.
64. Tighten the power steering pump stud nuts.
CAUTION: Torquing pulley with dimple facing power steering pump will bend the pulley.
NOTE: The dimple on pulley must face toward the front of the engine.
65. Install the power steering pump belt pulley.
66. Install the camshaft oil seal retainer.
- Install a new gasket and align the retainer on the locating dowels.
CAUTION: The running surface of the camshaft must not be damaged.
NOTE: Lubricate the seal with engine oil.
67. Use a Power Steering Pump Pulley Replacer, a Camshaft Seal Protector and a Camshaft Seal Replacer and install the camshaft oil seal.
1 Install camshaft seal protector.
2 Position a new seal and the camshaft seal replacer.
3 Install the power steering pulley replacer and install the seal.
68. Use a water pump pulley remover/replacer to install the water pump drive pulley.
69. Coat the mating faces of the cylinder heads with sealer.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
70. Install the LH spark plugs.
71. Install the RH spark plugs.
72. Install the cylinder head covers.
- Install new gaskets.
- Install the bolts in the indicated sequence.
73. Install the fuel charging wiring bracket to the cylinder head cover.
74. Install the LH engine lifting eye.
75. Coat the mating faces with sealer.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
- Apply a 10 mm diameter dot of sealer onto cylinder block at the indicated areas.
NOTE:
- Note the locations of the studs.
- Install the oil pan and torque bolts within six minutes of applying sealer.
76. Install the oil pan.
- Install a new gasket.
- Install the bolts and studs in the indicated sequence.
77. Position and install the oil pan heat shields.
78. On SVT equipped vehicles, Install the oil cooler.
- Apply WSE-M2C908-A engine oil to the oil cooler gasket, oil cooler insert O-ring, and oil filter gasket prior to installation.
79. Install the oil pressure switch.
NOTE: If studs were removed, install short end of studs into cylinder head.
80. Install the LH exhaust manifold with the catalytic converter.
- Install the bolts in the indicated sequence.
- Use a new gasket.
81. Install the oil filter.
82. Position the RH exhaust manifold and install the bolts.
83. Install the generator bracket.
84. Install the generator.
1 Install the generator bolts.
2 Install the bracket bolt.
85. Use a Rear Main Seal Replacer and the Rear Crankshaft Replacer adapters and install the crankshaft rear oil seal.
- Lubricate the outer ring and sealing lip with engine oil.
NOTE: Use a suitable strap wrench to hold the crankshaft pulley.
86. Install the flywheel.
1 Install the backing plate.
2 Install the flywheel and tighten the bolts working diagonally.
87. Install the water pump.
1 Position the pump.
2 Install new bolts and tighten them in two stages.
- Stage 1: 10 Nm
- Stage 2: 90°
88. Connect the water pump coolant hoses.
1 Connect the coolant hose to the oil filter adapter.
2 Connect the coolant hose to the cylinder block.
89. Install the water bypass tube.
- Use new O-rings and lubricate them with coolant.
- Use Premium Cooling System Fluid E2FZ-19549-AA or -B or equivalent meeting Ford specification ESE-M97B44-A.
90. Install the PCV valve and hoses.
1 Connect the PCV valve and hoses.
2 Install the PCV valve bracket nut.
91. Install the water pump drive belt.
- Rotate the belt tensioner clockwise to relieve tension on the belt.
92. Install the LH engine lifting eye.
1 Position the lifting eye.
2 Install the lifting eye bolt.
NOTE: Install the O ring on the dipstick tube prior to installation.
93. Install the dipstick tube and bolt.
1 Position the dipstick tube using a twisting motion.
2 Install the dipstick tube bolt.
94. Install the coolant distribution tube and bolts.
95. Install the thermostat housing with the coolant hoses.
NOTE: Install new gaskets with the locating lugs facing downwards.
96. Install the lower part of the intake manifold.
- Install the bolts in the indicated sequence.
97. Install the fuel injection system wiring harness.
1 Reconnect the fuel injector electrical connectors beginning at the front of the engine.
2 Reconnect the ECT sensor electrical connector.
3 Reconnect the DPFE sensor electrical connector.
98. Connect the CKP sensor electrical connector.
1 Connect the harness clip.
2 Connect the CKP sensor electrical connector.
99. Connect the CMP sensor electrical connector.
1 Connect the harness clip.
2 Connect the CMP sensor electrical connector.
100. Connect the oil pressure switch electrical connector.
101. Connect the heated oxygen sensor (H02S) electrical connector.
NOTE: Install new gaskets with the locating lugs pointing downwards.
102. Install the upper part of the intake manifold.
- Install the bolts in the indicated sequence.
103. Connect the throttle position (TP) sensor electrical connector.
104. Connect the PCV hose to the throttle body.
105. Connect the idle air control (IAC) valve electrical connector.
106. Position the vacuum harness and connect the vacuum lines.
1 Position the vacuum harness and connect the two vacuum supply hoses to the intake manifold.
2 Connect the electronic vacuum regulator (EVR) vacuum hoses.
3 Connect the fuel pressure regulator vacuum hose.
4 Connect the DPFE vacuum hoses.
5 Connect the EGR valve vacuum hoses.
107. Install the ignition coil.
1 Position the coil.
2 Position the capacitor.
3 Position the ground strap.
4 Install the ignition coil bolts.
5 Connect the ignition coil electrical connector.
108. Install the IMRC control unit.
1 Install the IMRC bolts.
2 Connect the IMRC electrical connector.
109. Connect the IMRC cable.
1 Connect the cable to the retainer.
2 Connect the cable end.
110. Position the wiring harness.
111. Connect the engine coolant temperature sensor electrical connector.
112. Connect the EGR vacuum regulator (EVR) electrical connector.
113. Connect the DPFE sensor electrical connector.
114. Connect the generator electrical connections.
1 Install the battery lead.
2 Install the field lead.
3 Position the battery lead cover.
115. Install the connecting shaft bracket to the cylinder block.