Steps 59 - 117

59. Using the special tools, install the crankshaft front oil seal.
^ Lubricate the outer ring and sealing lip with engine oil.

60. Apply silicon gasket and sealant F7AZ-19554-EA meeting Ford specification WSE-M4G323-A4 to the front of the crankshaft on the inside diameter surface of the crankshaft pulley at the keyway. Before applying the sealant, clean sealing surfaces with metal surface cleaner F7AZ19A536-RA meeting Ford specification WSE-M513392-A to remove all residues that may interfere with the sealants ability to adhere.

61. Note: Use the crankshaft pulley bolt washer for installation.





Using the special tool, install the crankshaft pulley.

62. Note: Use a new bolt.





Install the crankshaft pulley.
1. Use a suitable strap wrench to hold the crankshaft pulley.
2. 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 degrees





63. Install the power steering pump and bracket.
^ Loosely install all bolts and studs.

64. Note: The longer 84 mm bolts should be tightened first.





Tighten the power steering pump bolts.





65. Tighten the power steering pump stud nuts.

66. Caution: Tightening the pulley with the dimple facing the power steering pump, will bend the pulley.

Note: The dimple on the pulley must face toward the front of the engine.





Install the power steering pump belt pulley.





67. Install the camshaft oil seal retainer.
^ Use a new gasket and align the retainer on the locating dowels.

68. Caution: The running surface of the camshaft must not be damaged.

Note: Lubricate the camshaft oil seal with engine oil.





Using the special tools, install the camshaft oil seal.
1. Install the special tool.
2. Position a new seal and the special tool.
3. Install the special tool and install the seal.





69. Using the special tool, install the water pump drive pulley.





70. Coat the mating faces of the cylinder heads with sealant.
^ Use silicone gasket and sealant F7AZ-19554EA meeting Ford specification WSE-M4G323A4.





71. Install the left-hand spark plugs.





72. Install the right-hand spark plugs.

73. Note: Install the bolts in the indicated sequence.





Install the cylinder head covers.
^ Use new gaskets.





74. Install the fuel charging wiring bracket to the cylinder head cover.





75. Coat the mating faces with sealant.
^ Use silicone gasket and sealant F7AZ-19554EA meeting Ford specification WSE-M4G323A4.
^ Apply a 10 mm diameter dot of sealant onto the cylinder block at the indicated areas.

76. Note: Note the locations of the studs.

Note: Install the bolts and studs in the indicated sequence.

Note: Install the oil pan and tighten the bolts within six minutes of applying sealant.





Install the oil pan.
^ Use a new gasket.





77. Install the oil pressure switch.

78. Note: If studs were removed, install short end of studs into cylinder head.

Note: Install the nuts in the indicated sequence.





Install the left-hand exhaust manifold with the catalytic converter.
^ Use a new gasket.





79. Install the oil filter.





80. Position the right-hand exhaust manifold and install the nuts in the indicated sequence.





81. Install the generator bracket.





82. Install the generator.
1. Install the generator bolts.
2. Install the bracket bolt.

83. Note: Alternate bolt tightening to correctly seat the crankshaft rear oil seal until it is flush with the cylinder block.





Using the special tools, install the crankshaft rear oil seal. Lubricate the outer ring and sealing lip with engine oil.

84. Note: Use a suitable strap wrench to hold the crankshaft pulley.





Install the flywheel.
1. Install the backing plate.
2. Install the flywheel and tighten the bolts working diagonally.





85. 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 degrees





86. 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.





87. Install the water bypass. Use new O-ring seals and lubricate them with coolant.





88. Install the positive crankcase ventilation valve and hoses.
1. Connect the positive crankcase ventilation valve and hoses.
2. Install the bracket nut.





89. Install the water pump drive belt. Rotate the belt tensioner clockwise to relieve tension on the belt.





90. Install the left-hand engine lifting eye.
1. Position the lifting eye.
2. Install the bolt.

91. Note: Install the O-ring seal on the oil level indicator tube and lubricate with clean engine oil before installation.





Install the oil level indicator tube.
1. Position the oil level indicator tube using a twisting motion.
2. Install the oil level indicator tube bracket bolt.





92. Install the coolant distribution tube.





93. Install the thermostat housing with the coolant hoses.

94. Note: Use new gaskets with the locating lugs facing downwards.

Note: Install the bolts in the indicated sequence.





Install the lower part of the intake manifold.





95. Install the fuel injection system wiring harness.
1. Connect the fuel injector electrical connectors beginning at the front of the engine.
2. Connect the ECT sensor electrical connector.
3. Connect the DPFE sensor electrical connector.





96. Connect the CKP sensor electrical connector.
1. Connect the harness clip.
2. Connect the CKP sensor electrical connector.





97. Connect the CMP sensor electrical connector.
1. Connect the harness clip.
2. Connect the CMP sensor electrical connector.





98. Connect the oil pressure switch electrical connector.





99. Connect the Heated Oxygen Sensor (H02S) electrical connector.

100. Note: Use new gaskets with the locating lugs pointing downwards.

Note: Install the bolts in the indicated sequence.





Install the upper part of the intake manifold.





101. Connect the Throttle Position (TP) sensor and the fuel injector pressure sensor electrical connectors.





102. Connect the positive crankcase ventilation hose to the throttle body.





103. Connect the Idle Air Control (IAC) valve electrical connector.





104. Position the vacuum harness and connect the vacuum lines.





105. Connect the EGR valve, fuel pressure sensor or fuel pressure regulator and intake manifold vacuum hoses.





106. Install the ignition coil.
1. Position the coil.
2. Position the capacitor.
3. Position the ground cable.
4. Install the bolts.
5. Connect the ignition coil electrical connector.
107. Connect the six spark plug wires to the spark plugs.





108. Install the IMRC control unit.
1. Install the bolts.
2. Connect the electrical connector.





109. Connect the IMRC cable.
1. Connect the cable to the retainer.
2. Connect the cable end.

110. Position the wiring harness.





1ll. Attach the wiring harness to the right-hand valve cover and install two nuts.





112. Attach the in-line connectors to the bracket.





113. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.





114. Connect the EGR vacuum regulator solenoid electrical connector.





115. Connect the DPFE sensor electrical connector.





116. Connect the generator electrical connections.
1. Install the battery positive voltage cable.
2. Install the voltage regulator electrical connector.
3. Position the stator circuit electrical connector.





117. Install the connecting shaft bracket to the cylinder block.