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2013 ENGINE Engine Mechanical - 2.0L - Transit Connect

2013 ENGINE

Engine Mechanical - 2.0L - Transit Connect

SPECIFICATIONS
MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS
Item Specification Fill Capacity
High Temperature 4x4 Front Axle and Wheel Bearing Grease WSS-M1C267-
-
XG-11 A1
Motorcraft® Metal Surface Prep
- -
ZC-31-A
Motorcraft® Orange Antifreeze/Coolant Concentrated WSS-M97B44-
-
VC-3-B (US); CVC-3-B2 (Canada) D
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil
4.25L (4.5 qt)
(US); Motorcraft® SAE 5W-20 Super Premium Motor Oil WSS-M2C945-
includes filter
(Canada) A
change
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Multi-Purpose Grease
ESB-M1C93-B -
Motorcraft® XL-5 (aerosol) and/or CRC® SL3151
Silicone Brake Caliper Grease and Dielectric Compound ESE-M1C171-
-
XG-3-A A
Silicone Gasket and Sealant WSE-M4G323-
-
TA-30 A4
Motorcraft® Silicone Gasket Remover
- -
ZC-30
Thread Sealant with PTFE WSK-
-
TA-24 M2G350-A2

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Item Specification
Engine
Displacement 2.0L
No. of cylinders 4
Bore/stroke 87.5/83.1
Firing order 1-3-4-2
Oil pressure (hot @ 2, 000 RPM) 200-268 kPa (29-39 psi)
Engine weight (without accessory drive
115.8 kg (255.3 lb)
components and flexplate)
Engine and transaxle assembly weight 203.8 kg (449.3 lb)

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(without accessory drive components)

Cylinder Block
Cylinder bore diameter 87.5-87.53 mm (3.444-3.445 in)
Cylinder bore maximum out-of-round 0.008 mm (0.0003 in)
Main bearing bore diameter 57.020-57.038 mm (2.244-2.245 in)
0.1 mm/general 0.05 mm/200 x 200 (0.004 in/general)
Head gasket surface flatness
(0.0019 in/7.87 x 7.87)
Piston
Diameter (1) 87.5-87.51 mm (3.444-3.445 in)
Diameter (2) 87.51-87.52 mm (3.4452-3.4456 in)
Diameter (3) 87.52-87.53 mm (3.444-3.446 in)
Piston-to-bore clearance 0.025-0.045 mm (0.0009-0.0017 in)
Ring groove width - top 1.203-1.205 mm (0.0473-0.0474 in)
Ring groove width - 2nd 1.17-1.19 mm (0.0.460-0.0468 in)
Ring groove width - oil 2.501-2.503 mm (0.0984-0.0985 in)
Piston skirt coating thickness 0.008-0.020 mm (0.0003-0.0007 in)
Piston Pin
Diameter 20.995-21.0 mm (0.8266-0.8268 in)
Length 59.6-60.4 mm (2.346-2.377 in)
Piston-to-pin clearance 0.008-0.016 mm (0.0003-0.0006 in)
Pin-to-rod clearance Press fit
Cylinder Head
0.08 mm (0.0031 in) maximum overall, a maximum of
Cylinder head flatness
0.05 mm (0.0019 in) within 150 mm (5.9 in)
Valve lift @ zero lash (exhaust) 7.7 mm (0.30 in)
Valve lift @ zero lash (intake) 8.8 mm (0.35 in)
Valve guide diameter 5.509-5.539 mm (0.216-0.218 in)
Valve seat width - intake/exhaust 0.99-1.84 mm (0.038-0.072 in)
Valve seat angle 45 degrees
Valve seat runout 0.075 mm (0.0029 in)
Valve lash adjuster bore diameter 31.00-31.03 mm (1.220-1.221 in)
Cam bore diameter 25.015-25.040 mm (0.984-0.985 in)
Valve
Valve head diameter - intake 34.85-35.15 mm (1.372-1.383 in)
Valve head diameter - exhaust 29.85-30.15 mm (1.175-1.187 in)
Valve stem diameter - intake 5.470-5.485 mm (0.2153-0.2159 in)
Valve stem diameter - exhaust 5.465-5.480 mm (0.2151-0.2157 in)
Valve stem-to-guide clearance - intake 0.0027 mm (0.0001 in)
Valve stem-to-guide clearance - exhaust 0.0029 mm (0.00011 in)
Valve face runout 0.05 mm (0.001 in)
Valve face angle 45 degrees

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Valve Spring - Compression Pressure

Intake and exhaust (installed) 17.5 kg (38.667 lb)
Intake (valve open) 8.9 mm (0.35 in) of lift 44 kg (97.032 lb)
Exhaust (valve open) 7.4 mm (0.29 in) of lift 42 kg (93.338 lb)
Free length 44.92 mm (1.768 in)
Assembled height 37.9 mm (1.492 in)
Crankshaft
Main bearing journal diameter 51.980-52.000 mm (2.046-2.047 in)
Production repair 51.730-51.750 mm (2.036-2.037 in)
Main bearing clearance 0.017-0.047 mm (0.0007-0.0018 in)
Connecting rod journal diameter 49.980-50.000 mm (1.967-1.968 in)
Production repair 49.730-49.750 mm (1.957-1.958 in)
End play 0.22-0.43 mm (0.008-0.016 in)
Rings
Width - top 1.17-1.185 mm (0.0460-0.0466 in)
Width - 2nd 1.197-1.199 mm (0.0471-0.0472 in)
Width - oil 2.38-2.45 mm (0.093-0.096 in)
Ring gap (in bore) - top 0.16-0.31 mm (0.006-0.012 in)
Ring gap (in bore) - 2nd 0.33-0.48 mm (0.012-0.018 in)
Ring gap (in bore) - oil 0.2-0.7 mm (0.007-0.027 in)
Valve Tappet
Diameter 30.97-30.98 mm (1.2192-1.2196 in)
Tappet-to-valve clearance - intake 0.22- 0.28 mm (0.008-0.011 in)
Tappet-to-valve clearance - exhaust 0.27-0.33 mm (0.010-0.013 in)
Tappet-to-bore clearance 0.02-0.06 mm (0.0007-0.0023 in)
Camshaft
Lobe lift - intake 8.24999 mm (0.324 in)
Lobe lift - exhaust 7.80007 mm (0.307 in)
Runout (1)(1) 0.03 mm (0.001 in)
Thrust clearance 0.09-0.24 mm (0.003-0.009 in)
Journal diameter 24.96-24.98 mm (0.982-0.983 in)
Journal-to-bore clearance 0.035-0.080 mm (0.001-0.003 in)
Connecting Rod
Bearing clearance 0.027-0.052 mm (0.001-0.002 in)
Bearing thickness 1.496-1.520 mm (0.058-0.059 in)
Crank bore diameter 53.025-53.045 mm (2.087-2.088 in)
Pin bore diameter 20.965-20.985 mm (0.825-0.826 in)
Length (center to center) 154.8 mm (6.094 in)
Side clearance 1.95-3.05 mm (0.076-0.120 in)
Axial clearance 0.14-0.36 mm (0.005-0.014 in)
No. 3 Journal - Supported by No. 1 and No. 5 journals.

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(1)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
lb- lb-
Description Nm
ft in
Accessory drive belt idler pulley bolt 25 18 -
Accessory drive belt splash shield bolts 9 - 80
A/C compressor bolts and stud bolt 25 18 -
A/C compressor tube bracket nuts 10 - 89
A/C tube-to-compressor nut 15 - 133
Bellhousing-to-engine bolts 48 35 -
Bellhousing-to-engine stud bolt 48 35 -
Bellhousing-to-oil pan bolts 48 35 -
Camshaft bearing caps(1) - - -
Camshaft drive gear bolts 72 53 -
Connecting rod bearing cap bolts(1) - - -
Coolant degas bottle bolt 8 - 71
Coolant outlet bolts 10 - 89
Coolant pump bolts 10 - 89
Coolant pump pulley bolts 20 - 177
Crankshaft rear seal with retainer plate bolts(1) - - -
Crankshaft Position (CKP) sensor bolts(1) - - -
Crankshaft pulley bolt(1) - - -
Crankcase vent oil separator bolts 10 - 89
Cylinder head bolts(1) - - -
Cylinder Head Temperature (CHT) sensor 12 - 106
EGR tube 55 41 -
EGR valve bolts 20 - 177
Engine front cover bolts(1) - - -
Engine front cover-to-oil pan bolts 10 - 89
Engine ground wire bolt 48 35 -
Engine lifting eye bolts 45 33 -
Engine mount bolts 48 35 -
Engine mount nuts 90 66 -
Engine Oil Pressure (EOP) switch 15 - 133
Engine oil filter(2) - - -
Engine plug bolt 20 - 177
Engine-to-bellhousing bolts 48 35 -

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Engine-to-bellhousing stud bolt 48 35 -

Exhaust manifold heat shield bolts 10 - 89
Exhaust manifold nuts(1) - - -
Exhaust manifold studs 17 - 150
Flexplate bolts(1) - - -
Fuel rail bolt 25 18 -
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector
25 18 -
bracket nuts
Ignition coil-on-plug bolts 10 - 89
Intake manifold bolts 18 - 159
Intermediate shaft bracket bolts 48 35 -
Knock Sensor (KS) 20 - 177
Lifting eye bolts 45 33 -
Main bearing beam bolts(1) - - -
Negative battery cable ground bolt 10 - 89
Negative battery terminal ground wire nut 10 - 89
Oil cooler bolt 34 25 -
Oil filter adapter bolts 25 18 -
Oil level indicator tube bolt 10 - 89
Oil pan drain plug 28 21 -
Oil pan bolts(1) - - -
Oil pan-to-bellhousing bolts 48 35 -
Oil pump drive chain tensioner shoulder bolt 10 - 89
Oil pump drive chain tensioner bolt 10 - 89
Oil pump bolts(1) - - -
Oil pump screen and pickup tube bolts 10 - 89
Oil pump sprocket bolt 25 18 -
Oil squirters 4 - 35
Positive battery cable nut 10 - 89
Power steering tube bolt 18 - 159
Power steering tube bracket nut 20 - 177
Power steering tube clip bolt 10 - 89
Radio interference capacitor bracket bolt 10 - 89
Radio interference capacitor ground bolt 10 - 89
Spark plugs 12 - 106
Starter motor bolt 35 26 -
Starter motor stud bolt 35 26 -
Starter relay large nut 12 - 106
Starter relay small nut 5 - 44
Thermostat housing bolts 10 - 89

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Timing chain guide bolts 10 - 89

Timing chain tensioner bolts 10 - 89
Torque converter-to-flexplate nuts 35 26 -
Transaxle mounting nut mount plate center nut 150 111 -
Transaxle mounting nut mount plate outer nuts 48 35 -
Transaxle roll-restrictor bolts 70 52 -
Valve cover bolts(1) - - -
Wiring harness bracket bolts 10 - 89
(1) See procedure for specification.

(2) Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter
adapter.

DESCRIPTION AND OPERATION

ENGINE

The 2.0L 4-cylinder engine has the following features:

l Dual overhead camshaft

l Four valves per cylinder
l Sequential Multi-Port Fuel Injection (SFI)
l Aluminum cylinder head
l Aluminum cylinder block
l Electronic ignition system with coil-on-plug 4 ignition coils

The 2.0L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a coil-on-plug
ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder
assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to
provide greater strength. The camshafts are mounted in the cylinder heads and act against valve tappets to open
and close the valves. The camshafts are driven off the front of the cylinder head by one timing chain. The chain
is driven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a cast
iron connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven by the same
sprocket that drives the timing chain.

Engine Identification

Always refer to these labels when installation of new parts is necessary or when checking engine calibrations.
The engine parts often differ within a CID family. Verification of the identification codes will make sure the
correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional
equipment and revisions.

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following:

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Fig. 1: Identifying Engine Code Information Label

Courtesy of FORD MOTOR CO.

Item Description
1 Engine part number
2 Bar code
3 Dearborn engine plant
4 Engine displacement
5 Bar code
6 Running number
7 Engine build date (DDMMYY)
8 Plant shift line

Engine Cylinder Identification

Fig. 2: Engine Cylinder Identification

Courtesy of FORD MOTOR CO.

Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in
the ENGINE CONTROLS - INTRODUCTION (EXCEPT DIESEL & HYBRID) (SECTION 0) .

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Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel
injectors:

l are mounted in the cylinder head.

l meter fuel into the air intake stream in accordance with engine demand.
l are positioned so that their tips direct fuel just ahead of the engine intake valves.
l supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure
sensor is positioned upstream from the fuel injectors on the fuel injection supply manifold.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake manifold.

Lubrication System

The engine lubrication system operates as follows:

l Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
l Oil is pumped through the oil filter on the left front side of the cylinder block.
l Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder head.
l From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the
connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod
bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting
rod, piston and piston ring assembly.

DIAGNOSIS AND TESTING

ENGINE

Refer to ENGINE SYSTEM - GENERAL INFORMATION for basic mechanical concerns or refer to the
ENGINE CONTROLS - INTRODUCTION (EXCEPT DIESEL & HYBRID) (SECTION 0) for
driveability concerns.

GENERAL PROCEDURES
VALVE CLEARANCE CHECK

1. Remove the valve cover. For additional information, refer to VALVE COVER .
2. Remove the 2 bolts and accessory drive belt splash shield.
l To install, tighten to 9 Nm (80 lb-in).

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Fig. 3: Locating Accessory Drive Belt Splash Shield And Bolts

Courtesy of FORD MOTOR CO.

NOTE: Turn the engine clockwise only, and use the crankshaft bolt only.

NOTE: Measure each valve's clearance at base circle, with the lobe pointed away
from the tappet, before removing the camshafts. Failure to measure all
clearances prior to removing the camshafts will necessitate repeated
removal and installation and wasted labor time.

Fig. 4: Measuring Valve Clearance Using Feeler Gauge

Courtesy of FORD MOTOR CO.

3. Use a feeler gauge to measure each valve's clearance and record its location.

NOTE: The number on the valve tappet only reflects the digits that follow the
decimal. For example, a tappet with the number 0.650 has the thickness of
3.650 mm.

NOTE: The nominal desired mid-range clearance is:

l intake: 0.25 mm (0.0095 in).

l exhaust: 0.30 mm (0.0115 in).

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Select tappets using this formula: tappet thickness = measured

clearance + the existing tappet thickness - nominal clearance.

NOTE: The acceptable clearances after being fully installed are:

l intake: 0.22-0.28 mm (0.008-0.011 in).

l exhaust: 0.27-0.33 mm (0.010-0.013 in).

4. Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
5. If any tappets do not measure within specifications, install new tappets in these locations. For additional
information, refer to VALVE TRAIN COMPONENTS - EXPLODED VIEW and VALVE
TAPPETS .

IN-VEHICLE REPAIR
INTAKE MANIFOLD

Intake Manifold (View 1 of 3)

Fig. 5: View Of Intake Manifold (1 Of 3)

Courtesy of FORD MOTOR CO.

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Item Part Number Description

1 14A464 Engine Oil Pressure (EOP) switch electrical connector (part of 12C508)
2 - Wire harness retainer (part of 12C508)
3 14A464 Electronic throttle control electrical connector (part of 12C508)
4 9D289 Fuel vapor return hose
5 14A464 Manifold Absolute Pressure (MAP) sensor electrical connector (part of 12C508)
6 14A624 Knock Sensor (KS) electrical connector with retainer (part of 12C508)

Intake Manifold (View 2 of 3)

Fig. 6: View Of Intake Manifold (2 Of 3)

Courtesy of FORD MOTOR CO.

Item Part Number Description

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1 13A506 Wire harness pin-type retainer (part of 12C508) (4 required)

2 7A020 Transaxle fluid indicator
3 19D848 Power brake booster vacuum tube

Intake Manifold (View 3 of 3)

Fig. 7: View Of Intake Manifold (3 Of 3) With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 W500311 Intake manifold bolt (6 required)
2 W500312 Intake manifold bolts
3 9424 Intake manifold
4 6758 PCV hose

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5 9439 Intake manifold gasket

6 9E470 EGR tube

Removal

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the Air Cleaner (ACL) and outlet pipe. For additional information, refer to INTAKE AIR
DISTRIBUTION & FILTERING .
3. Remove the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR
AND TUBE .
4. Remove the fuel rail. For additional information, refer to FUEL CHARGING AND CONTROLS -
2.0L .
5. Remove the transaxle fluid indicator.
6. Remove the intake manifold lower bolt.

Fig. 8: Locating Intake Manifold Lower Bolt

Courtesy of FORD MOTOR CO.

7. Detach the engine wiring harness pin-type retainer from the intake manifold.

Fig. 9: Locating Engine Wiring Harness Pin-Type Retainer From Intake Manifold
Courtesy of FORD MOTOR CO.

8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wire harness
retainer from the starter stud bolt.

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9. Disconnect the electronic throttle control electrical connector.

10. Disconnect the fuel vapor return hose.
11. Disconnect the power brake booster vacuum tube.
l Depress the quick release locking ring.

l Pull the vacuum tube out of the quick release fitting.

Fig. 10: Locating Vacuum Tube Of Quick Release Fitting

Courtesy of FORD MOTOR CO.

12. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
13. Detach the wiring harness retainer from the intake manifold and disconnect the Knock Sensor (KS)
electrical connector.
14. Detach the 4 wiring harness pin-type retainers from the intake manifold.

NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also
retain a crash bracket to the intake manifold. The 2 bolts are equipped with
an attachment feature that allows them to be loosened but remain attached
to the intake manifold. Do not attempt to remove the 2 bolts or the crash
bracket from the intake manifold.

Fig. 11: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

15. Loosen the 2 intake manifold bolts.

16. Remove the 5 intake manifold bolts.

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Fig. 12: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

17. Remove the EGR tube from the cylinder head.

18. Disconnect the PCV hose and remove the intake manifold.

Installation

NOTE: 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.

Fig. 13: Locating Intake Manifold Gaskets

Courtesy of FORD MOTOR CO.

1. Inspect and install new intake manifold gaskets if necessary.

2. Position the intake manifold and connect the PCV hose.
3. Install the EGR tube.
l Tighten to 55 Nm (41 lb-ft).

4. Attach the wiring harness retainer to the intake manifold and connect the KS electrical connector.

NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also
retain a crash bracket to the intake manifold. The 2 bolts are equipped with
an attachment feature that allows them to be loosened but remain attached
to the intake manifold. Do not attempt to remove the 2 bolts or the crash

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bracket from the intake manifold.

Fig. 14: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

5. Install the intake manifold and hand-tighten the 2 intake manifold bolts.
6. Install the 5 intake manifold mounting bolts.
l Tighten all 7 bolts to 18 Nm (159 lb-in).

Fig. 15: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

7. Attach the 4 wiring harness pin-type retainers to the intake manifold.

8. Connect the MAP sensor electrical connector.
9. Connect the power brake booster vacuum tube.
l Push the vacuum tube into the quick release fitting.

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Fig. 16: Locating Vacuum Tube Of Quick Release Fitting

Courtesy of FORD MOTOR CO.

10. Connect the fuel vapor return hose.

11. Connect the electronic throttle control electrical connector.
12. Connect the EOP switch electrical connector and attach the wire harness retainer to the starter stud bolt.
13. Attach the engine wiring harness pin-type retainer to the intake manifold.

Fig. 17: Locating Engine Wiring Harness Pin-Type Retainer From Intake Manifold
Courtesy of FORD MOTOR CO.

14. Install the lower intake manifold bolt.

l Tighten to 18 Nm (159 lb-in).

Fig. 18: Locating Intake Manifold Lower Bolt

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Courtesy of FORD MOTOR CO.

15. Install the transaxle fluid indicator.

16. Install the fuel rail. For additional information, refer to FUEL CHARGING AND CONTROLS - 2.0L .
17. Install the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR
AND TUBE .
18. Install the Air Cleaner (ACL) and outlet pipe. For additional information, refer to INTAKE AIR
DISTRIBUTION & FILTERING .

VALVE COVER

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® Metal Surface Prep
-
ZC-31-A
Silicone Gasket and Sealant
WSE-M4G323-A4
TA-30

Valve Cover (View 1 of 2)

Fig. 19: Exploded View Of Valve Cover (1 Of 2) With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 14A464 Camshaft Position (CMP) sensor electrical connector (part of 12C508)
2 14A464 Ignition coil-on-plug electrical connector (part of 12C508) (4 required)
3 W500215 Ignition coil-to-valve cover bolt (4 required)
4 12A192 Ignition coil (4 required)
5 14A464 Cylinder Head Temperature (CHT) sensor electrical connector (part of 12C508)
6 6853 Crankcase breather tube
7 14A169 Wire harness retainers (part of 12C508) (3 required)
8 - Generator B+ wire harness retainer (3 required)
9 14A464 Generator electrical connector (part of 12C508)

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10 W500031 Radio interference capacitor bracket bolt

11 W705661 Radio interference capacitor ground bolt
12 14K005 Radio interference capacitor bracket

Valve Cover (View 2 of 2)

Fig. 20: Exploded View Of Valve Cover (2 Of 2)

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6C295 Valve cover bolt (2 required)
2 6C293 Valve cover stud bolt (12 required)
3 6K272 Valve cover
4 6K260 Valve cover gasket

Removal

NOTE: During engine repair procedures, cleanliness is extremely important. 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.

1. Disconnect the Camshaft Position (CMP) sensor electrical connector.

2. Disconnect the 4 ignition coil-on-plug electrical connectors.
3. Remove the 4 ignition coil-to-valve cover bolts and the ignition coils.
4. Lift up the connector boot and disconnect the Cylinder Head Temperature (CHT) sensor electrical
connector.
5. Disconnect the crankcase breather tube from the valve cover.
6. Detach the 6 wiring harness retainers from the valve cover stud bolts.
7. Disconnect the generator electrical connector.
8. Remove the radio interference capacitor bracket bolt.
9. Remove the radio interference capacitor ground bolt and position the bracket aside.

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10. Remove the 14 valve cover retainers, the valve cover and gasket.
l Discard the valve cover gasket.

Fig. 21: Locating Valve Cover Retainers

Courtesy of FORD MOTOR CO.

Installation

NOTE: 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.

1. Clean and inspect the sealing surfaces.

2. Apply silicone gasket and sealant to the locations shown in illustration.

Fig. 22: Locating Sealant Applying Area On Valve Cover

Courtesy of FORD MOTOR CO.

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 prep.

3. Install the valve cover, a new gasket and the 14 retainers.

l Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).

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Fig. 23: Identifying Valve Cover Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

4. Position the radio interference capacitor bracket and install the bolt.
l Tighten to 10 Nm (89 lb-in).

5. Install the radio interference capacitor ground bolt.

l Tighten to 10 Nm (89 lb-in).

6. Connect the generator electrical connector.

7. Attach the 6 wiring harness retainers to the valve cover stud bolts.
8. Connect the crankcase breather tube on the valve cover.
9. Connect the CHT sensor electrical connector and install the connector boot.
10. Install the ignition coils and the 4 ignition coil-to-valve cover bolts.
l Tighten to 10 Nm (89 lb-in).

11. Connect the 4 ignition coil-on-plug electrical connectors.

12. Connect the CMP sensor electrical connector.

LOWER END COMPONENTS - EXPLODED VIEW

Crankshaft Pulley and Crankshaft Front Seal

Fig. 24: Exploded View Of Crankshaft Pulley And Crankshaft Front Seal

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Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6K340 Crankshaft pulley bolt
2 - Crankshaft pulley washer (part of 6K340)
3 6316 Crankshaft pulley
4 6700 Crankshaft front seal
5 6378 Diamond washer

Flexplate and Crankshaft Rear Seal With Retainer Plate

Fig. 25: Exploded View Of Flexplate And Crankshaft Rear Seal With Retainer Plate With Torque
Specifications
Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6379 Flexplate bolt (6 required)
2 6477 Flexplate
3 6730 Oil pan drain plug
4 W500215 Engine front cover bolt (4 required)
5 W706284 Oil pan bolt (2 required)
6 W500224 Oil pan bolt (11 required)
7 6675 Oil pan
8 W500212 Crankshaft rear oil seal with retainer plate bolt (6 required)
9 6K318 Crankshaft rear oil seal with retainer plate

1. For additional information, refer to the procedures in this information.

CRANKSHAFT PULLEY

SPECIAL TOOLS

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Alignment Plate, Camshaft

303-465 (T94P-6256-CH)

Holding Tool, Crankshaft Damper

303-1416

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Timing Peg, Crankshaft TDC

303-507

GENERAL EQUIPMENT
6 mm x 18 mm bolt

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal

NOTE: 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, otherwise
severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. 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.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the RH wheel and tire. For additional information, refer to WHEELS AND TIRES .
3. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
4. Remove the valve cover. For additional information, refer to VALVE COVER .

NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in
damage to the engine. Turn the engine in the normal direction of rotation
only.

5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead
Center (TDC).
l The hole in the crankshaft pulley should be in the 6 o'clock position.

Fig. 26: Turning Crankshaft Clockwise

Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this
tool to prevent engine rotation can result in engine damage.

NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate
cannot be installed, rotate the crankshaft one complete revolution
clockwise to correctly position the camshafts.

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Fig. 27: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

6. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.

Fig. 28: Locating Engine Plug Bolt

Courtesy of FORD MOTOR CO.

NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it
from turning past TDC. However, the crankshaft can still be rotated in the
counterclockwise direction. The crankshaft must remain at the TDC
position during the crankshaft pulley removal and installation.

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Fig. 29: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

8. Install the Crankshaft TDC Timing Peg.

NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during
removal of the pulley bolt or damage to the engine can occur. Therefore,
the crankshaft pulley must be held in place with the Crankshaft Damper
Holding Tool, and the bolt should be removed using an air impact wrench
(1/2-in drive minimum).

NOTE: The crankshaft sprocket diamond washer may come off with the
crankshaft pulley. The diamond washer must be replaced. Remove and
discard the diamond washer. If the diamond washer is not installed,
engine damage may occur.

9. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft
pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
l Remove and discard the crankshaft pulley bolt and washer.

l Remove the crankshaft pulley.

l Remove the diamond washer and discard.

Fig. 30: Holding Crankshaft Pulley

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Courtesy of FORD MOTOR CO.

Installation

1. Install a new diamond washer.

NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

Fig. 31: Locating Crankshaft Pulley Position

Courtesy of FORD MOTOR CO.

2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.

NOTE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Fig. 32: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

3. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.

NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during
installation of the pulley bolt or damage to the engine can occur.

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Therefore, the crankshaft pulley must be held in place with the Crankshaft
Damper Holding Tool and the bolt should be installed using hand tools
only.

NOTE: Do not reuse the crankshaft pulley bolt.

4. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive
hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
l Stage 1: Tighten to 100 Nm (74 lb-ft).

l Stage 2: Tighten an additional 90 degrees (one-fourth turn).

Fig. 33: Holding Crankshaft Pulley

Courtesy of FORD MOTOR CO.

5. Remove the 6 mm x 18 mm bolt.

Fig. 34: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

6. Remove the Crankshaft TDC Timing Peg.

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Fig. 35: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

7. Remove the Camshaft Alignment Plate.

Fig. 36: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

8. Turn the crankshaft clockwise one and three-fourths turns.

9. Install the Crankshaft TDC Timing Peg.

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Fig. 37: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

Fig. 38: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

10. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.

NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

11. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
l If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this
procedure.

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Fig. 39: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

12. Install the Camshaft Alignment Plate to check the position of the camshafts.
l If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be
corrected by repeating this procedure.

Fig. 40: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

13. Remove the Camshaft Alignment Plate.

Fig. 41: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

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14. Remove the 6 mm x 18 mm bolt.

Fig. 42: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

15. Remove the Crankshaft TDC Timing Peg.

Fig. 43: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

16. Install the engine plug bolt.

l Tighten to 20 Nm (177 lb-in).

17. Install the valve cover. For additional information, refer to VALVE COVER .
18. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
19. Install the RF wheel and tire. For additional information, refer to WHEELS AND TIRES .

CRANKSHAFT FRONT SEAL

SPECIAL TOOLS

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Installer, Camshaft Front Oil Seal

303-096 (T74P-6150-A)

Remover, Oil Seal

303-409 (T92C-6700-CH)

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal

NOTE: 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

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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, otherwise
severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. 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.

1. Remove the crankshaft pulley. For additional information, refer to LOWER END COMPONENTS -
EXPLODED VIEW and CRANKSHAFT PULLEY .

NOTE: Use care not to damage the engine front cover or the crankshaft when
removing the seal.

Fig. 44: Removing Crankshaft Front Oil Seal Using Oil Seal Remover
Courtesy of FORD MOTOR CO.

2. Using the Oil Seal Remover, remove the crankshaft front oil seal.

Installation

NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.

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Fig. 45: Installing Crankshaft Front Oil Seal Using Camshaft Front Oil Seal Installer
Courtesy of FORD MOTOR CO.

1. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to LOWER END COMPONENTS -
EXPLODED VIEW and CRANKSHAFT PULLEY .

FLEXPLATE

SPECIAL TOOLS

Holding Tool, Flywheel

303-103 (T74P-8375-A)

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Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the transaxle. For additional information, refer to AUTOMATIC
TRANSAXLE/TRANSMISSION - 4F27E .
3. Install the Flywheel Holding Tool and remove the 6 flexplate bolts and the flexplate. Discard the bolts.

Fig. 46: Identifying Flywheel Holding Tool On Flexplate

Courtesy of FORD MOTOR CO.

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Installation

NOTE: Special bolts are used for installation. Do not use standard bolts.

1. Install the flexplate.

2. Install the Flywheel Holding Tool.

Fig. 47: Identifying Flywheel Holding Tool On Flexplate

Courtesy of FORD MOTOR CO.

3. Tighten the new bolts in the sequence shown in 3 stages:

l Stage 1: Tighten to 50 Nm (37 lb-ft).

l Stage 2: Tighten to 80 Nm (50 lb-ft).

l Stage 3: Tighten to 112 Nm (83 lb-ft).

Fig. 48: Identifying Flexplate Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

4. Install the transaxle. For additional information, refer to AUTOMATIC

TRANSAXLE/TRANSMISSION - 4F27E .

CRANKSHAFT REAR SEAL WITH RETAINER PLATE

SPECIAL TOOLS

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Installer, Crankshaft Rear Main Oil Seal

303-328 (T88P-6701-B1)

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® Metal Surface Prep
-
ZC-31-A
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Silicone Gasket and Sealant WSE-M4G323-
TA-30 A4
Motorcraft® Silicone Gasket Remover
-
ZC-30

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the flexplate. For additional information, refer to FLEXPLATE .
3. Drain the engine oil.
l Install the drain plug and tighten to 28 Nm (21 lb-ft).

4. Remove the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR
AND TUBE .

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NOTE: If the oil pan is not removed damage to the rear oil seal retainer joint can
occur.

5. Remove the 17 bolts and the oil pan.

6. Remove the 6 bolts and the crankshaft rear seal with retainer plate.

Installation

1. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate
onto the crankshaft.

Fig. 49: Identifying Crankshaft Rear Main Oil Seal Installer

Courtesy of FORD MOTOR CO.

2. Install the crankshaft rear seal with retainer plate and 6 bolts.
l Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).

Fig. 50: Crankshaft Rear Oil Seal Retainer Plate Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other

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abrasive means to clean the sealing surfaces. These tools cause scratches
and gouges, which make leak paths. Use a plastic scraping tool to remove
traces of sealant.

3. Clean and inspect all the oil pan, cylinder block and front cover flange mating surfaces.

NOTE: If not secured 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. Follow the directions on the packaging.
Failure to follow this procedure can cause future oil leakage.

NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of
applying the silicone gasket and sealant.

4. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the oil pan.
l Install the oil pan and the 2 bolts finger-tight.

Fig. 51: Locating Oil Pan Bolts

Courtesy of FORD MOTOR CO.

5. Install the 4 engine front cover-to-oil pan bolts.

l Tighten to 10 Nm (89 lb-in).

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Fig. 52: Locating Engine Front Cover-To-Oil Pan Bolts

Courtesy of FORD MOTOR CO.

6. Install the remaining oil pan bolts.

l Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).

Fig. 53: Identifying Oil Pan Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

7. Install the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR
AND TUBE .
8. Install the flexplate. For additional information, refer to FLEXPLATE .
9. Fill the engine with clean engine oil.

ENGINE FRONT COVER

SPECIAL TOOLS

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Aligner, Crankshaft Sensor

303-1417

Installer, Camshaft Front Oil Seal

303-096 (T74P-6150-A)

Remover, Oil Seal

303-409 (T92C-6700-CH)

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GENERAL EQUIPMENT
6 mm x 18 mm bolt

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Silicone Gasket and Sealant WSE-M4G323-
TA-30 A4

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Fig. 54: Exploded View Of Engine Front Cover With Torque Specifications
Courtesy of FORD MOTOR CO.

Item Part Number Description

1 14A464 Crankshaft Position (CKP) sensor electrical connector (part of 12A690)
2 13A506 Wiring harness retainer (part of 12A690) (2 required)
3 W701219 CKP sensor bolt (2 required)
4 6C315 CKP sensor
5 6700 Crankshaft front seal
6 W500221 Coolant pump pulley bolt (3 required)
7 8509 Coolant pump pulley
8 W500215 Engine front cover bolt (17 required)
9 W500300 Engine front cover bolt
10 W500320 Engine front cover bolt
11 W500328 Engine front cover bolt (3 required)
12 6019 Engine front cover

Removal

NOTE: 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

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requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and
camshafts must be locked in place by the special service tools, otherwise
severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Loosen the 3 coolant pump pulley bolts.
3. Remove the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
4. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
l Detach the 2 wiring harness retainers from the engine front cover.

5. Remove the 2 bolts and the CKP sensor.

NOTE: Use care not to damage the engine front cover or the crankshaft when
removing the seal.

Fig. 55: Removing Crankshaft Front Oil Seal Using Oil Seal Remover
Courtesy of FORD MOTOR CO.

6. Using the Oil Seal Remover, remove the crankshaft front oil seal.
7. Remove the 3 bolts and the coolant pump pulley.
8. Remove the coolant degas bottle. For additional information, refer to ENGINE COOLING .
9. Remove the power steering pump. For additional information, refer to POWER STEERING .
10. Remove the engine mount. For additional information, refer to ENGINE MOUNT .
11. Slightly raise the engine for access to the accessory drive idler pulley.
12. Remove the accessory drive idler pulley. For additional information, refer to ACCESSORY DRIVE .
13. Remove the bolts and the engine front cover.

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Fig. 56: Locating Engine Front Cover Bolts

Courtesy of FORD MOTOR CO.

Installation

NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other
abrasive means to clean sealing surfaces. These tools cause scratches
and gouges which make leak paths.

1. Clean and inspect the mounting surfaces of the engine and the front cover.

NOTE: The engine front cover must be installed and the bolts tightened within 4
minutes of applying the silicone gasket and sealant.

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Fig. 57: Locating Bead Of Silicone Gasket And Sealant Applying Area On Front Cover
Courtesy of FORD MOTOR CO.

2. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas.
Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
3. Install the engine front cover. Tighten the bolts in the sequence shown in illustration, to the following
specifications:
l Tighten the 8-mm bolts to 10 Nm (89 lb-in).

l Tighten the 13-mm bolts to 48 Nm (35 lb-ft).

Fig. 58: Identifying Engine Front Cover Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

4. Install the accessory drive idler pulley. For additional information, refer to ACCESSORY DRIVE .
5. Lower the engine to the installed position.
6. Install the engine mount. For additional information, refer to ENGINE MOUNT .
7. Install the power steering pump. For additional information, refer to POWER STEERING .
8. Install the coolant degas bottle. For additional information, refer to ENGINE COOLING .
9. Install the coolant pump pulley and the 3 bolts.
l Do not tighten at this time.

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NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.

Fig. 59: Installing Crankshaft Front Oil Seal Using Camshaft Front Oil Seal Installer
Courtesy of FORD MOTOR CO.

10. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
11. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .

NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

Fig. 60: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

12. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
13. Install the CKP sensor and the 2 bolts.
l Do not tighten the bolts at this time.

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Fig. 61: Locating CKP Sensor Bolts

Courtesy of FORD MOTOR CO.

14. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
l Tighten the 2 bolts to 7 Nm (62 lb-in).

Fig. 62: Adjusting CKP Sensor Using Crankshaft Sensor Aligner

Courtesy of FORD MOTOR CO.

15. Connect the CKP sensor electrical connector.

l Attach the 2 wiring harness retainers to the engine front cover.

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Fig. 63: Locating CKP Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

16. Remove the 6 mm x 18 mm bolt.

Fig. 64: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

17. Tighten the coolant pump pulley bolts.

l Tighten to 20 Nm (177 lb-in).

18. Fill the power steering system. For additional information, refer to STEERING SYSTEM .

TIMING DRIVE COMPONENTS

Removal

NOTE: 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, otherwise
severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the engine front cover. For additional information, refer to ENGINE FRONT COVER .

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3. Compress the timing chain tensioner in the following sequence.

1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing
the timing chain arm toward the tensioner.
3. Insert a paper clip into the hole to retain the tensioner.

Fig. 65: Compressing Timing Chain Tensioner Using Small Pick

Courtesy of FORD MOTOR CO.

4. Remove the 2 bolts and the timing chain tensioner.

Fig. 66: Locating Timing Chain Tensioner Bolts

Courtesy of FORD MOTOR CO.

5. Remove the RH timing chain guide.

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Fig. 67: Locating RH Timing Chain Guide

Courtesy of FORD MOTOR CO.

6. Remove the timing chain.

Fig. 68: Locating Timing Chain

Courtesy of FORD MOTOR CO.

7. Remove the bolts and the LH timing chain guide.

Fig. 69: Locating LH Timing Chain Guide Bolts

Courtesy of FORD MOTOR CO.

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NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation.
Damage to the tool or the camshaft can occur.

NOTE: Intake camshaft drive gear shown in illustration, exhaust camshaft drive
gear similar.

8. Remove the bolts and the camshaft drive gears.

l Use the flats on the camshaft to prevent camshaft rotation.

Fig. 70: Locating Camshaft Drive Gear And Bolt

Courtesy of FORD MOTOR CO.

Installation

1. Install the camshaft drive gears and the bolts. Do not tighten the bolts at this time.

Fig. 71: Locating Camshaft Drive Gear Bolts

Courtesy of FORD MOTOR CO.

2. Install the LH timing chain guide and bolts.

l Tighten to 10 Nm (89 lb-in).

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Fig. 72: Locating LH Timing Chain Guide Bolts

Courtesy of FORD MOTOR CO.

3. Install the timing chain.

Fig. 73: Locating Timing Chain

Courtesy of FORD MOTOR CO.

4. Install the RH timing chain guide.

Fig. 74: Locating RH Timing Chain Guide

Courtesy of FORD MOTOR CO.

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NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned
in the compressed position, follow the next 4 steps.

NOTE: Do not compress the ratchet assembly. This will damage the ratchet
assembly.

Fig. 75: Compressing Timing Chain Tensioner Plunger

Courtesy of FORD MOTOR CO.

5. Using the edge of a vise, compress the timing chain tensioner plunger.
6. Using a small pick, push back and hold the ratchet mechanism.

Fig. 76: Holding Ratchet Mechanism Using Small Pick

Courtesy of FORD MOTOR CO.

7. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

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Fig. 77: Pushing Ratchet Arm Back Into Tensioner Housing

Courtesy of FORD MOTOR CO.

8. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in
during installation.

Fig. 78: Holding Ratchet Assembly Using Paper Clip

Courtesy of FORD MOTOR CO.

9. Install the timing chain tensioner and the 2 bolts.

l Tighten to 10 Nm (89 lb-in).

l Remove the paper clip to release the piston.

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Fig. 79: Locating Timing Chain Tensioner And Bolts

Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this
tool to prevent engine rotation can result in engine damage.

10. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts.
l Tighten to 72 Nm (53 lb-ft).

Fig. 80: Locating Camshaft Drive Gear Bolts

Courtesy of FORD MOTOR CO.

11. Install the front cover. For additional information, refer to ENGINE FRONT COVER .

CAMSHAFTS

SPECIAL TOOLS

Alignment Plate, Camshaft

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303-465 (T94P-6256-CH)

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal

NOTE: During engine repair procedures, cleanliness is extremely important. 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: Do not rotate the camshafts unless instructed to in this procedure. Rotating the
camshafts or crankshaft with timing components loosened or removed can
cause serious damage to the valves and pistons.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the coolant expansion tank. For additional information, refer to ENGINE COOLING .
3. Remove the RF wheel and tire. For additional information, refer to WHEELS AND TIRES .
4. Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK .
5. Remove the timing drive components. For additional information, refer to TIMING DRIVE
COMPONENTS .
6. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.

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Fig. 81: Locating Camshaft Lobe Position

Courtesy of FORD MOTOR CO.

7. Remove the Camshaft Alignment Plate.

Fig. 82: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

NOTE: Failure to follow the camshaft loosening procedure can result in damage
to the camshafts.

NOTE: Mark the location and orientation of each camshaft bearing cap.

8. Remove the camshafts from the engine.

l Loosen the camshaft bearing cap bolts, in sequence, one turn at a time.

l Repeat the first step until all tension is released from the camshaft bearing caps.

l Remove the camshaft bearing caps.

l Remove the camshafts.

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Fig. 83: Identifying Camshaft Bearing Cap Bolts Loosening Sequence

Courtesy of FORD MOTOR CO.

Installation

NOTE: Install the camshafts with the alignment slots in the camshafts lined up so
the Camshaft Alignment Plate can be installed without rotating the
camshafts. Make sure the lobes on the No. 1 cylinder are in the same
position as noted in the removal procedure. Rotating the camshafts when
the timing chain is removed, or installing the camshafts 180 degrees out of
position can cause severe damage to the valves and pistons.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.

1. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps
in the sequence shown in 3 stages:
l Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until finger-tight.

l Stage 2: Tighten to 7 Nm (62 lb-in).

l Stage 3: Tighten to 16 Nm (142 lb-in).

Fig. 84: Identifying Camshaft Bearing Cap Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

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2. Install the Camshaft Alignment Plate.

Fig. 85: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

3. Install the timing drive components. For additional information, refer to TIMING DRIVE
COMPONENTS
4. Install the RF wheel and tire. For additional information, refer to WHEELS AND TIRES .
5. Install the coolant expansion tank. For additional information, refer to ENGINE COOLING .

VALVE TRAIN COMPONENTS - EXPLODED VIEW

Fig. 86: Exploded View Of Valve Train

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6500 Valve tappet (16 required)

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2 6518 Valve collet (16 required)

3 6514 Valve spring retainer (16 required)
4 6513 Valve spring (16 required)
5 6517 Valve seal (16 required)

1. For additional information, refer to the procedures in this information.

VALVE SPRINGS

SPECIAL TOOLS

Compressor, Valve Spring

303-300 (T87C-6565-A)

Compressor, Valve Spring

303-350 (T89P-6565-A)

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Compressor, Valve Spring

303-472 (T94P-6565-AH)

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Multi-Purpose Grease

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Motorcraft® XL-5 (aerosol) and/or CRC® SL3151 ESB-M1C93-B

Removal

NOTE: During engine repair procedures, cleanliness is extremely important. 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the camshafts. For additional information, refer to CAMSHAFTS .

NOTE: If the camshafts and valve tappets are to be reused, mark the location of
the valve tappets to make sure they are assembled in their original
positions.

NOTE: The number on the valve tappets only reflects the digits that follow the
decimal. For example, a tappet with the number 0.650 has the thickness of
3.650 mm.

3. Remove and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM -
GENERAL INFORMATION .
4. Remove the spark plugs. For additional information, refer to ENGINE IGNITION - 2.0L .

NOTE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the
compressed air from the cylinder until the valve spring, valve spring
retainer and valve collet is installed. Any loss of air pressure will allow the
valve to fall into the cylinder.

5. Connect the compressed air supply to cylinder No. 1.

NOTE: Place all parts in order to one side.

6. Apply compressed air to the cylinder and remove the valve spring.
l Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using
some multi-purpose grease and a small screwdriver.
l Remove the valve spring retainer and the valve spring.

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Fig. 87: Compressing Valve Spring Using Valve Spring Compressors

Courtesy of FORD MOTOR CO.

Installation

NOTE: Check the seating of the valve collet.

1. Using the Valve Spring Compressors, install the valve spring.

l Insert the valve spring and the valve spring retainer.

l Compress the valve spring and install the valve collet using some grease and a small screwdriver.

Fig. 88: Compressing Valve Spring Using Valve Spring Compressors

Courtesy of FORD MOTOR CO.

2. Disconnect the compressed air supply.

3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to ENGINE IGNITION - 2.0L .
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to CAMSHAFTS .

VALVE SEALS

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SPECIAL TOOLS

Compressor, Valve Spring

303-300 (T87C-6565-A)

Compressor, Valve Spring

303-350 (T89P-6565-A)

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Compressor, Valve Spring

303-472 (T94P-6565-AH)

Installer, Valve Stem Oil Seal

303-470 (T94P-6510-CH)

Remover, Valve Stem Oil Seal

303-468 (T94P-6510-AH)

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Slide Hammer
307-005 (T59L-100-B)

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Multi-Purpose Grease
ESB-M1C93-B
Motorcraft® XL-5 (aerosol) and/or CRC® SL3151

Removal

NOTE: During engine repair procedures, cleanliness is extremely important. 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

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failure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the camshafts. For additional information, refer to CAMSHAFTS .

NOTE: If the camshafts and valve tappets are to be reused, mark the location of
the valve tappets to make sure they are assembled in their original
positions.

NOTE: The number on the valve tappets only reflects the digits that follow the
decimal. For example, a tappet with the number 0.650 has the thickness of
3.650 mm.

3. Remove and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM -
GENERAL INFORMATION .
4. Remove the spark plugs. For additional information, refer to ENGINE IGNITION - 2.0L .

NOTE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the
compressed air from the cylinder until the valve spring, valve spring
retainer and valve collet is installed. Any loss of air pressure will allow the
valve to fall into the cylinder.

5. Connect the compressed air supply to the No. 1 cylinder.

NOTE: Place all parts in order to one side.

6. Apply compressed air to the cylinder and remove the valve spring.
l Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using
some multi-purpose grease and a small screwdriver.
l Remove the valve spring retainer and the valve spring.

Fig. 89: Compressing Valve Spring Using Valve Spring Compressors

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Courtesy of FORD MOTOR CO.

7. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seal.

Fig. 90: Removing Valve Seal Using Valve Stem Oil Seal Remover
Courtesy of FORD MOTOR CO.

Installation

1. Install the valve stem seal installation sleeve.

Fig. 91: Identifying Valve Stem Seal Installation Sleeve

Courtesy of FORD MOTOR CO.

2. Using the Valve Stem Oil Seal Installer, install the valve seal.

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Fig. 92: Installing Valve Seal Using Valve Stem Oil Seal Installer
Courtesy of FORD MOTOR CO.

NOTE: Check the seating of the valve collet.

3. Using the Valve Spring Compressors, install the valve spring.

l Insert the valve spring and the valve spring retainer.

l Compress the valve spring and install the valve collet using some multi-purpose grease and a small
screwdriver.

Fig. 93: Compressing Valve Spring Using Valve Spring Compressors

Courtesy of FORD MOTOR CO.

4. Disconnect the compressed air supply.

5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Install the spark plugs. For additional information, refer to ENGINE IGNITION - 2.0L .
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to CAMSHAFTS .

VALVE TAPPETS

MATERIAL SPECIFICATIONS

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Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal and Installation

NOTE: During engine repair procedures, cleanliness is extremely important. 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the camshafts. For additional information, refer to CAMSHAFTS .

NOTE: If the camshafts and valve tappets are to be reused, mark the location of
the valve tappets to make sure they are assembled in their original
positions.

NOTE: The number on the valve tappets only reflects the digits that follow the
decimal. For example, a tappet with the number 0.650 has the thickness of
3.650 mm.

3. Remove and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM -
GENERAL INFORMATION .
4. To install, reverse the removal procedure.
l Coat the valve tappets with clean engine oil prior to installation.

CYLINDER HEAD

SPECIAL TOOLS

Alignment Plate, Camshaft

303-465 (T94P-6256-CH)

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Engine Support Bar

303-F072

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® Metal Surface Prep
-
ZC-31-A
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Silicone Gasket and Sealant WSE-M4G323-
TA-30 A4
Motorcraft® Silicone Gasket Remover -

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ZC-30

Cylinder Head (View 1 of 2)

Fig. 94: Exploded View Of Cylinder Head (1 Of 2)

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6500 Valve tappet (16 required)
2 6A284 Camshaft bearing cap (10 required)
3 W703383 Camshaft bearing cap bolt (20 required)
4 6A272 Exhaust camshaft
5 6A267 Intake camshaft

Cylinder Head (View 2 of 2)

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Fig. 95: Exploded View Of Cylinder Head (2 Of 2) With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 14A464 EGR valve electrical connector (part of 12B637)
2 8287 Upper radiator hose clamp
3 8260 Upper radiator hose
4 W52592 EGR coolant tube clamp
5 18K580 EGR coolant hose (part of heater hose)
6 - Engine coolant vent hose clamp (part of 8W005)
7 8W005 Engine coolant vent hose
8 - Heater hose clamp (part of 18K580)
9 18K580 Heater hose
10 W525958 Bypass hose clamp
11 8548 Bypass hose
12 W500204 Wiring harness bracket bolt (2 required)
13 14A301 Wiring harness bracket
14 6065 Cylinder head bolt (10 required)
15 6050 Cylinder head
16 6051 Cylinder head gasket

Removal

NOTE: 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, otherwise
severe engine damage can occur.

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NOTE: During engine repair procedures, cleanliness is extremely important. 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .
3. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND
CABLES .
4. Remove the generator. For additional information, refer to CHARGING SYSTEM .
5. Remove the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD .
6. Clean and inspect the exhaust manifold flange. For additional information, refer to exhaust manifold
cleaning and inspection in ENGINE SYSTEM - GENERAL INFORMATION .
7. Drain the cooling system. For additional information, refer to ENGINE COOLING .
8. Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK .
9. Remove the engine oil filter and discard.

Fig. 96: Locating Engine Oil Filter

Courtesy of FORD MOTOR CO.

10. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .
11. Remove the timing drive components. For additional information, refer to TIMING DRIVE
COMPONENTS .
12. Remove the Camshaft Alignment Plate.

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Fig. 97: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

13. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.

Fig. 98: Locating Camshaft Lobe Position

Courtesy of FORD MOTOR CO.

NOTE: Failure to follow the camshaft loosening procedure may result in damage
to the camshafts.

NOTE: Mark the location and orientation of each camshaft bearing cap.

14. Remove the camshafts from the engine.

l Loosen the camshaft bearing cap bolts, in sequence, one turn at a time.

l Repeat the first step until all tension is released from the camshaft bearing caps.

l Remove the camshaft bearing caps.

l Remove the camshafts.

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Fig. 99: Identifying Camshaft Bearing Cap Bolts Loosening Sequence

Courtesy of FORD MOTOR CO.

NOTE: If the camshafts and valve tappets are to be reused, mark the location of
the valve tappets to make sure they are assembled in their original
positions.

15. Remove the valve tappets.

NOTE: The number on the valve tappets only reflects the digits that follow the
decimal. For example, a tappet with the number 0.650 has the thickness of
3.650 mm.

16. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .
17. Remove the 3 bolts and position the wiring harness and bracket aside.
18. Disconnect the EGR valve electrical connector.
19. Disconnect the coolant hoses from the coolant bypass.
20. Disconnect the EGR coolant hose.
21. Lower the engine and remove the Engine Support Bar.
22. Remove the 10 bolts and the cylinder head.
l Discard the bolts.

23. Remove and discard the head gasket.

24. Inspect the cylinder head mating surfaces. For additional information, refer to ENGINE SYSTEM -
GENERAL INFORMATION .

Installation

NOTE: 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 that make leak paths. Use a plastic scraping tool to remove all
traces of the head gasket.

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NOTE: Observe all warnings or cautions and follow all application directions
contained on the packaging of the silicone gasket remover and the metal
surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be
used to clean and prepare the surfaces.

1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block
in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket
remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and
to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some
staining of the metal surfaces is normal.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign
material is removed.
3. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and
the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .
4. Apply silicone gasket and sealant to the locations shown in illustration.

Fig. 100: Locating Sealant Applying Area On Cylinder Block

Courtesy of FORD MOTOR CO.

5. Install a new cylinder head gasket.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New
cylinder head bolts must be installed.

6. Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5

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stages.
l Stage 1: Tighten to 5 Nm (44 lb-in).

l Stage 2: Tighten to 15 Nm (133 lb-in).

l Stage 3: Tighten to 45 Nm (33 lb-ft).

l Stage 4: Turn 90 degrees.

l Stage 5: Turn an additional 90 degrees.

Fig. 101: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

7. Install the Engine Support Bar and raise the engine.

Fig. 102: Installing Engine Support Bar

Courtesy of FORD MOTOR CO.

8. Install the EGR coolant hose.

9. Connect the coolant hoses onto the coolant bypass.
10. Connect the EGR valve electrical connector.
11. Position the wire harness bracket and install the 3 bolts.
l Tighten to 10 Nm (89 lb-in).

NOTE: Lubricate the valve tappets with clean engine oil.

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Fig. 103: Locating Valve Tappet

Courtesy of FORD MOTOR CO.

12. Install the valve tappets in their original positions.

NOTE: Install the camshafts with the alignment notches in the camshafts lined up
so the camshaft alignment plate can be installed. Make sure the lobes on
the No. 1 cylinder are in the same position at noted in the removal
procedure. Failure to follow this procedure can cause severe damage to
the valves and pistons.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.

13. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps
in the sequence shown in 3 stages:
l Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until the cam is fully seated.

l Stage 2: Tighten to 7 Nm (62 lb-in).

l Stage 3: Tighten to 16 Nm (142 lb-in).

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Fig. 104: Identifying Camshaft Bearing Cap Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

14. Install the timing drive components. For additional information, refer to TIMING DRIVE
COMPONENTS .
15. Install the valve cover. For additional information, refer to VALVE COVER .
16. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
17. Install the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD .
18. Install the generator. For additional information, refer to CHARGING SYSTEM .
19. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
20. Drain the engine oil.
l Install the drain plug and tighten to 28 Nm (21 lb-ft).

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Fig. 105: Locating Drain Plug

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing
the oil filter.

21. Install a new engine oil filter.

l Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter
adapter.

Fig. 106: Locating Engine Oil Filter

Courtesy of FORD MOTOR CO.

22. Fill the engine with clean engine oil.

23. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .

ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW

Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP) Switch

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Fig. 107: Identifying Oil Filter, Oil Filter Adapter, Oil Cooler And Engine Oil Pressure (EOP) Switch
With Torque Specifications
Courtesy of FORD MOTOR CO.

Item Part Number Description

1 14A464 Engine Oil Pressure (EOP) switch electrical connector (part of 12C508)
2 9278 EOP switch
3 6714 Oil filter
4 W500025 Oil filter adapter bolt (4 required)
5 6884 Oil filter adapter
6 6A636 Oil filter adapter gasket
7 - Coolant hose clamp (2 required)
8 - Coolant hose (2 required)
9 W706487 Oil cooler bolt
10 6A642 Oil cooler

Transaxle Bolts for Oil Pan Removal

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Fig. 108: Identifying Transaxle Bolts For Oil Pan Removal With Torque Specifications
Courtesy of FORD MOTOR CO.

Part
Item Description
Number
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector
1 W520103
bracket nut (2 required)
2 14301 HO2S and CMS wire connector bracket
3 W500124 Upper bellhousing-to-engine stud bolt
4 W500121 Upper bellhousing-to-engine bolt
5 W500125 LH bellhousing-to-engine bolts (2 required)

Oil Pan, Oil Pump Screen and Pickup Tube

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Fig. 109: Identifying Oil Pan, Oil Pump Screen And Pickup Tube And Bolts With Torque Specifications
Courtesy of FORD MOTOR CO.

Item Part Number Description

6 W500124 RH engine-to-bellhousing stud bolt
7 W500120 RH engine-to-bellhousing bolt
8 W500121 Bellhousing-to-oil pan bolt (2 required)
9 W500121 Oil pan-to-bellhousing bolt (2 required)
10 6730 Oil pan drain plug
11 W500215 Engine front cover-to-oil pan bolt (4 required)
12 W706284 Oil pan bolt (2 required)
13 W500224 Oil pan bolt (11 required)
14 6675 Oil pan
15 W706282 Oil pump screen and pickup tube bolt (2 required)
16 6622 Oil pump screen and pickup tube
17 6625 Oil pump screen and pickup tube gasket

Oil Pump

Fig. 110: Exploded View Of Oil Pump With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 W703651 Oil pump drive chain tensioner shoulder bolt (2 required)
2 6C271 Oil pump drive chain tensioner
3 6A895 Oil pump drive chain
4 W704397 Oil pump sprocket bolt
5 6652 Oil pump sprocket
6 W703647 Oil pump bolt (4 required)
7 6600 Oil pump

1. For additional information, refer to the procedures in this information.

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OIL FILTER ADAPTER

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Thread Sealant with PTFE WSK-M2G350-
TA-24 A2

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
3. Disconnect the 2 coolant hoses from the oil cooler.
4. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
5. Remove the EOP switch.
6. Remove and discard the oil filter.
7. Remove the 4 bolts and the oil filter adapter.
l Discard the gasket.

Installation

1. Using a new gasket, install the oil filter adapter and the 4 bolts.
l Tighten to 25 Nm (18 lb-ft).

NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing
the oil filter.

2. Install a new oil filter.

l Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter
adapter.

NOTE: Apply thread sealant to the EOP switch threads.

3. Install the EOP switch.

l Tighten to 15 Nm (133 lb-in).

4. Connect the EOP switch electrical connector.

5. Connect the 2 coolant hoses to the oil cooler.
6. Top off the engine with clean engine oil.
7. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .

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ENGINE OIL PRESSURE (EOP) SWITCH

MATERIAL SPECIFICATIONS
Item Specification
Thread Sealant with PTFE
WSK-M2G350-A2
TA-24

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch.
l To install, tighten to 15 Nm (133 lb-in).

NOTE: Apply thread sealant to the EOP switch threads.

4. To install, reverse the removal procedure.

OIL PAN

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® Metal Surface Prep
-
ZC-31-A
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Silicone Gasket and Sealant WSE-M4G323-
TA-30 A4

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND
CABLES .

NOTE: To prevent damage to the transmission, do not loosen the transmission-

to-engine bolts more than 5 mm (0.19 in).

3. Loosen the upper bellhousing-to-engine bolt and stud bolt 5 mm (0.19 in).
4. Remove the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR
AND TUBE .

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5. Loosen the 2 LH bellhousing-to-engine bolts 5 mm (0.19 in).

6. Loosen the RH engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
7. Remove the 2 bellhousing-to-oil pan bolts.
8. Remove the 2 oil pan-to-bellhousing bolts.
9. Slide the transaxle rearward 5 mm (0.19 in).
10. Remove the 2 bolts and the accessory drive belt splash shield.

Fig. 111: Locating Accessory Drive Belt Splash Shield And Bolts
Courtesy of FORD MOTOR CO.

11. Drain the engine oil.

l Install the drain plug.

l Tighten to 28 Nm (21 lb-ft).

12. Remove the 4 engine front cover-to-oil pan bolts.

13. Remove the 13 bolts and the oil pan.

Installation

NOTE: 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. Use a plastic scraping tool to remove

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traces of sealant.

1. Clean and inspect all mating surfaces.

NOTE: If the oil pan is not secured within 10 minutes of sealant application, the
sealant must be removed and the sealing area cleaned with metal surface
prep. Allow to dry until there is no sign of wetness, or 10 minutes,
whichever is longer. Failure to follow this procedure can cause future oil
leakage.

Fig. 112: Locating Oil Pan Silicone Gasket And Sealant Bead Applying Area
Courtesy of FORD MOTOR CO.

2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil
pan-to-engine front cover mating surface.
3. Position the oil pan onto the engine and install the 13 oil pan bolts finger-tight.

NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the
front surface of the oil pan flush with the front surface of the engine block.

4. Install the 4 engine front cover-to-oil pan bolts.

l Tighten to 10 Nm (89 lb-in).

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Fig. 113: Locating Engine Front Cover-To-Oil Pan Bolts

Courtesy of FORD MOTOR CO.

5. Tighten the oil pan bolts in the sequence shown in illustration.

l Tighten to 25 Nm (18 lb-ft).

Fig. 114: Identifying Oil Pan Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

6. Install the accessory drive belt splash shield and the 2 bolts.
l Tighten to 9 Nm (80 lb-in).

Fig. 115: Locating Accessory Drive Belt Splash Shield And Bolts
Courtesy of FORD MOTOR CO.

7. Alternate tightening the 1 LH bellhousing-to-engine and 1 RH engine-to-bellhousing lower bolts to slide

the transaxle and engine together.
l Tighten to 48 Nm (35 lb-ft).

8. Tighten the remaining LH bellhousing-to-engine bolt and the remaining rear engine-to-bellhousing stud
bolt.
l Tighten to 48 Nm (35 lb-ft).

9. Install the 2 bellhousing-to-oil pan bolts.

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l Tighten to 48 Nm (35 lb-ft).

10. Install the 2 oil pan-to-bellhousing bolts.
l Tighten to 48 Nm (35 lb-ft).

11. Install the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR
AND TUBE .
12. Tighten the top bellhousing-to-engine bolt and stud bolt.
l Tighten to 48 Nm (35 lb-ft).

13. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
14. Fill the engine with clean engine oil.

OIL PUMP SCREEN AND PICKUP TUBE

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the oil pan. For additional information, refer to OIL PAN .
3. Remove the 2 bolts and the oil pump screen and pickup tube.
l Discard the gasket.

Installation

1. Clean and inspect all mating surfaces.

2. Using a new gasket, install the oil pump screen and pickup tube and the 2 bolts.
l Tighten to 10 Nm (89 lb-in).

3. Install the oil pan. For additional information, refer to OIL PAN .

OIL PUMP

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® Metal Surface Prep
-
ZC-31-A
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Silicone Gasket and Sealant WSE-M4G323-
TA-30 A4

Removal

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .

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2. Remove the engine front cover. For additional information, refer to ENGINE FRONT COVER .
3. Remove the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR
AND TUBE .
4. Drain the engine oil, then install the drain plug.
l To install, tighten to 28 Nm (21 lb-ft).

5. Remove the 2 oil pan-to-bellhousing bolts.

6. Remove the 2 bellhousing-to-oil pan bolts.
7. Remove the 13 bolts and the oil pan.

NOTE: Discard the gasket and clean and inspect the gasket mating surfaces.

8. Remove the 2 bolts and the oil pump screen and pickup tube.
9. Remove the oil pump drive chain tensioner.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the 2 shoulder bolts.

Fig. 116: Identifying Oil Pump Chain Drive Tensioner And Shoulder Bolts
Courtesy of FORD MOTOR CO.

10. Remove the chain from the oil pump sprocket.

11. Remove the bolt and oil pump sprocket.
12. Remove the 4 bolts and the oil pump.

Installation

NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface
prep.

1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:
l Stage 1: Tighten to 10 Nm (89 lb-in).

l Stage 2: Tighten to 20 Nm (177 lb-in).

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Fig. 117: Identifying Oil Pump Assembly Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

2. Install the oil pump sprocket and bolt.

l Tighten to 25 Nm (18 lb-ft).

3. Install the chain onto the oil pump sprocket.

4. Install the oil pump drive chain tensioner shoulder bolt.
l Tighten to 10 Nm (89 lb-in).

Fig. 118: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
Courtesy of FORD MOTOR CO.

5. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
l Tighten to 10 Nm (89 lb-in).

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Fig. 119: Locating Oil Pump Drive Chain Tensioner, Bolt And Tensioner Spring
Courtesy of FORD MOTOR CO.

6. Install the oil pump screen and pickup tube and the 2 bolts.
l Tighten to 10 Nm (89 lb-in).

NOTE: 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. Use a plastic scraping tool to remove
traces to sealant.

7. Clean all mating surfaces with metal surface prep.

NOTE: If the oil pan is not secured within 10 minutes of sealant application, the
sealant must be removed and the sealing area cleaned with metal surface
prep. Allow to dry until there is no sign of wetness, or 10 minutes,
whichever is longer. Failure to follow this procedure can cause future oil
leakage.

8. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan.
l Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.

Fig. 120: Locating Oil Pan Bolts

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Courtesy of FORD MOTOR CO.

9. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the
engine block.

Fig. 121: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block Using
Straightedge
Courtesy of FORD MOTOR CO.

10. Install the remaining oil pan bolts.

l Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).

Fig. 122: Identifying Oil Pan Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

11. Install the 2 bellhousing-to-oil pan bolts.

l Tighten to 48 Nm (35 lb-ft).

12. Install the 4 oil pan-to-bellhousing bolts.

l Tighten to 48 Nm (35 lb-ft).

13. Install the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR
AND TUBE .
14. Install the engine front cover. For additional information, refer to ENGINE FRONT COVER .

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15. Fill the engine with clean engine oil.

OIL LEVEL INDICATOR AND TUBE

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Fig. 123: Identifying Oil Level Indicator And Tube Components With Torque Specifications
Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6750 Oil level indicator
2 W500211 Oil level indicator tube bolt
3 6754 Oil level indicator tube
4 6754-B O-ring seal
5 - Wiring harness retainer

Removal and Installation

1. Remove the oil level indicator.

2. Remove the oil level indicator tube bolt.

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To install, tighten to 10 Nm (89 lb-in).

l

3. Detach the wiring harness retainer from the oil level indicator tube.

Fig. 124: Locating Wiring Harness Retainer From Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.

4. Remove the oil level indicator tube and discard the O-ring seal.
l To install, lubricate the new O-ring seal with clean engine oil.

5. To install, reverse the removal procedure.

OIL COOLER

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the oil drain plug and drain the engine oil.
l To install, tighten to 28 Nm (21 lb-ft).

3. Remove and discard the oil filter.

l To install, tighten three-fourths of a turn after the filter gasket makes contact with the oil filter
adapter.
4. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
5. Disconnect the 2 coolant hoses from the oil cooler.
6. Disconnect the Engine Oil Pressure (EOP) electrical connector.

NOTE: Discard the gasket.

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7. Remove the 4 bolts and the oil filter adapter.

l To install, tighten to 25 Nm (18 lb-ft).

NOTE: If metal or aluminum material is present in the oil cooler, mechanical

concerns exist. To diagnose mechanical concerns, refer to ENGINE
SYSTEM - GENERAL INFORMATION .

8. Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler.
l Inspect the oil cooler.

l To install, tighten to 34 Nm (25 lb-ft).

9. To install, reverse the removal procedure.

10. Fill the engine with clean engine oil.
11. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .

EXHAUST MANIFOLD

Fig. 125: Identifying Exhaust Manifold Components With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 14A464 Heated Oxygen Sensor (HO2S) electrical connector (part of 12C508)
2 - HO2S sensor wiring retainer
3 W713299 Exhaust manifold heat shield bolt (4 required)
4 9N454 Exhaust manifold heat shield
5 W713652 Exhaust manifold nut (7 required)
6 9430 Exhaust manifold
7 9448 Exhaust manifold gasket
8 W704474 Exhaust manifold stud (7 required)

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &

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LIFTING .
2. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
l Detach the wiring retainer.

4. Remove the 4 exhaust manifold heat shield bolts and the heat shield.
5. Remove and discard the 7 exhaust manifold nuts.
6. Remove the exhaust manifold and discard the exhaust manifold gasket.
7. Remove and discard the 7 exhaust manifold studs.
8. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM -
GENERAL INFORMATION .

Installation

1. Install the 7 new exhaust manifold studs.

l Tighten to 17 Nm (150 lb-in).

NOTE: Failure to tighten the catalytic converter nuts to specification before

installing the converter bracket bolts will cause the converter to develop
an exhaust leak.

NOTE: Failure to tighten the catalytic converter nuts to specification a second

time may cause the converter to develop an exhaust leak. Due to the
possibility of the catalytic converter nuts loosening after the first
tightening sequence, a second sequence (stage 2) will ensure that the
catalytic converter nuts are properly torqued.

2. Install a new exhaust manifold gasket, the exhaust manifold and 7 new nuts in the sequence shown in 2
stages:
l Stage 1: Tighten to 48 Nm (35 lb-ft).

l Stage 2: Tighten to 48 Nm (35 lb-ft).

Fig. 126: Identifying Exhaust Manifold Nuts Tightening Sequence

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Courtesy of FORD MOTOR CO.

3. Install the exhaust manifold heat shield and the 4 bolts.

l Tighten to 10 Nm (89 lb-in).

4. Connect the HO2S electrical connector.

l Attach the wiring retainer.

5. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .

ENGINE MOUNT

SPECIAL TOOLS

Engine Support Bar

303-F072

Coolant Degas Bottle

Fig. 127: Identifying Coolant Degas Bottle And Bolt With Torque Specifications

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Courtesy of FORD MOTOR CO.

Item Part Number Description

1 W701107 Coolant degas bottle bolt
2 8A080 Coolant degas bottle

Engine Mount

Fig. 128: Identifying Engine Mount Bolt And Nut With Torque Specifications
Courtesy of FORD MOTOR CO.

Item Part Number Description

1 W520214 Engine mount nut (2 required)
2 W710332 Engine mount bolt (3 required)
3 6F012 Engine mount

Removal and Installation

1. Remove the degas bottle bolt.

l To install, tighten to 8 Nm (71 lb-in).

2. Lift the coolant degas bottle off of the shock tower bracket and position it aside.
3. Install the Engine Support Bar.

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Fig. 129: Installing Engine Support Bar

Courtesy of FORD MOTOR CO.

4. Remove the 2 engine mount nuts.

l To install, tighten to 90 Nm (66 lb-ft).

5. Remove the 3 bolts and the engine mount.

l To install, tighten to 48 Nm (35 lb-ft).

6. To install, reverse the removal procedure.

REMOVAL
ENGINE

SPECIAL TOOLS

2, 200# Floor Crane, Fold Away

300-OTC1819E or equivalent

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Lifting Bracket, Engine

303-050 (T70P-6000)

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Powertrain Lift
300-OTC1585AE or equivalent

Retainer, Torque Converter

307-346 (T97T-7902-A)

Spreader Bar
303-D089 (D93P-6001-A3) or equivalent

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Adjustable Grip Arm, 1735A

014-00001 or equivalent

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Remove the 2 bolts, pin-type retainer and the LH front splash shield.

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Fig. 130: Locating LH Front Splash Shield, Pin-Type Retainer And Bolts
Courtesy of FORD MOTOR CO.

3. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .
4. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM -
GENERAL INFORMATION AND DIAGNOSTICS .
5. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR
DISTRIBUTION & FILTERING .
6. Disconnect the crankcase vent tube from the valve cover.

Fig. 131: Locating Crankcase Vent Tube

Courtesy of FORD MOTOR CO.

7. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND
CABLES .
8. Remove the nut and disconnect cable from the positive battery cable terminal.

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Fig. 132: Locating Positive Battery Cable Terminal And Nut

Courtesy of FORD MOTOR CO.

9. Detach the 3 positive battery cable wire harness retainers.

Fig. 133: Locating Positive Battery Cable Wire Harness Retainers

Courtesy of FORD MOTOR CO.

10. Remove the bolt and the negative battery cable ground.

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Fig. 134: Locating Negative Battery Cable Ground Bolt

Courtesy of FORD MOTOR CO.

NOTE: The vehicle should be given adequate time to completely cool prior to
disconnecting the fuel tube quick connecting coupling. This area is
directly above the exhaust manifold and precautions should be taken to
avoid any fuel spillage.

Fig. 135: Locating Fuel Tube Quick Connect Coupling From Fuel Tube Near Bulkhead
Courtesy of FORD MOTOR CO.

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11. Disconnect the fuel tube quick connect coupling from the fuel tube near the bulkhead. For additional
information, refer to FUEL SYSTEM - GENERAL INFORMATION .
12. Disconnect the Evaporative Emission (EVAP) tube and position aside. For additional information, refer
to FUEL SYSTEM - GENERAL INFORMATION .

Fig. 136: Locating Evaporative Emission (EVAP) Tube And Position Aside
Courtesy of FORD MOTOR CO.

13. Disconnect the power brake booster vacuum tube.

l Depress the quick connect locking ring.

l Pull the vacuum tube out of the quick connect fitting.

Fig. 137: Locating Vacuum Tube Of Quick Release Fitting

Courtesy of FORD MOTOR CO.

14. Detach and disconnect the 2 engine harness electrical connectors.

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Fig. 138: Locating Engine Harness Electrical Connectors

Courtesy of FORD MOTOR CO.

15. Detach the engine harness from the coolant outlet bracket harness retainer.

Fig. 139: Locating Engine Harness Of Coolant Outlet Bracket Harness Retainer
Courtesy of FORD MOTOR CO.

16. Remove the nut and the ground wire from the negative battery terminal.

Fig. 140: Locating Nut And Ground Wire From Negative Battery Terminal
Courtesy of FORD MOTOR CO.

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17. Disconnect the 3 PCM electrical connectors.

Fig. 141: Locating PCM Electrical Connectors

Courtesy of FORD MOTOR CO.

18. Disconnect the starter wire harness electrical connector.

Fig. 142: Locating Starter Wire Harness Electrical Connector

Courtesy of FORD MOTOR CO.

19. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors
and detach the wire harness retainer.

Fig. 143: Locating Heated Oxygen Sensor And Catalyst Monitor Sensor Electrical Connectors

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Courtesy of FORD MOTOR CO.

20. Disconnect the transaxle shift cable from the lever and bracket.

Fig. 144: Locating Transaxle Shift Cable

Courtesy of FORD MOTOR CO.

21. Remove the transmission fluid cooler tube secondary latches.

Fig. 145: Locating Transmission Fluid Cooler Tube Secondary Latches

Courtesy of FORD MOTOR CO.

NOTE: Transaxle fluid cooler inlet tube shown in illustration, transaxle fluid
cooler outlet tube similar.

22. Disconnect the 2 transaxle fluid cooler tubes from the transaxle.
1. Squeeze the tabs together.
2. Slide the transaxle fluid cooler tube lock up and remove the transaxle fluid cooler tubes from the
transaxle.

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Fig. 146: Sliding Transaxle Fluid Cooler Tube Lock Up

Courtesy of FORD MOTOR CO.

23. Remove the engine oil level indicator.

Fig. 147: Locating Engine Oil Level Indicator

Courtesy of FORD MOTOR CO.

24. Remove the 2 front wheels and tires. For additional information, refer to WHEELS AND TIRES .
25. Remove the accessory drive belt and tensioner. For additional information, refer to ACCESSORY
DRIVE .
26. Remove the generator. For additional information, refer to CHARGING SYSTEM .
27. Detach the 2 B+ battery cable wire harness retainers from the valve cover stud bolts and remove the
wiring harness.

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Fig. 148: Locating B+ Battery Cable Wire Harness Retainers From Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.

28. Remove the 2 A/C tube nuts from the A/C compressor.

Fig. 149: Locating A/C Tube-To-Compressor Nuts

Courtesy of FORD MOTOR CO.

29. Disconnect the 2 A/C tubes from the compressor.

l Discard the 2 O-ring seals.

Fig. 150: Locating A/C Tube O-Rings

Courtesy of FORD MOTOR CO.

30. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .

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31. Remove the cooling fan motor and shroud. For additional information, refer to ENGINE COOLING .
32. Disconnect the lower radiator hose from the radiator.

Fig. 151: Locating Lower Radiator Hose From Radiator

Courtesy of FORD MOTOR CO.

33. Drain the engine oil.

l Install the drain plug and tighten to 28 Nm (21 lb-ft).

Fig. 152: Locating Drain Plug

Courtesy of FORD MOTOR CO.

34. Remove the engine oil filter and discard.

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Fig. 153: Locating Engine Oil Filter

Courtesy of FORD MOTOR CO.

35. Remove the LH and RH halfshafts. For additional information, refer to FRONT DRIVE
HALFSHAFTS .
36. Remove the bolt and the power steering tube clip.

Fig. 154: Locating Power Steering Tube Clip Bolt

Courtesy of FORD MOTOR CO.

37. Remove the bolt and the power steering tubes from the steering gear.
l Discard the 2 power steering tube O-ring seals.

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Fig. 155: Locating Power Steering Tubes And Bolt

Courtesy of FORD MOTOR CO.

38. Disconnect the power steering cooler tube.

Fig. 156: Locating Power Steering Cooler Tube

Courtesy of FORD MOTOR CO.

39. Remove the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD .
40. Remove the power steering pump. For additional information, refer to POWER STEERING .
41. Release the retaining clip and disconnect the coolant degas bottle hose.

Fig. 157: Locating Coolant Degas Bottle Hose And Retaining Clip

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Courtesy of FORD MOTOR CO.

42. Disconnect the coolant degas bottle vent hose from the coolant bypass and position it aside.

Fig. 158: Locating Coolant Degas Bottle Vent Hose From Coolant Bypass
Courtesy of FORD MOTOR CO.

43. Disconnect the upper radiator hose and the heater hose from the coolant bypass.

Fig. 159: Locating Upper Radiator Hose And Heater Hose From Coolant Bypass
Courtesy of FORD MOTOR CO.

44. Disconnect the heater hose from the coolant tube.

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Fig. 160: Locating Heater Hose Of Coolant Tube

Courtesy of FORD MOTOR CO.

45. Remove the transaxle fluid level indicator.

Fig. 161: Locating Transaxle Fluid Level Indicator

Courtesy of FORD MOTOR CO.

NOTE: The bolts are different lengths, mark the bolts for installation.

Fig. 162: Locating Transaxle Roll Restrictor And Bolts

Courtesy of FORD MOTOR CO.

46. Remove the 2 bolts and the transaxle roll restrictor.

47. Remove the 2 lower bellhousing-to-oil pan bolts.

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Fig. 163: Locating Lower Bellhousing-To-Oil Pan Bolts

Courtesy of FORD MOTOR CO.

48. Remove the 2 oil pan-to-bellhousing bolts.

Fig. 164: Locating Oil Pan-To-Bell Housing Bolts

Courtesy of FORD MOTOR CO.

49. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the lift table.

Fig. 165: Securing Engine To Lift Table Using Powertrain Lift And Adjustable Grip Arm
Courtesy of FORD MOTOR CO.

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50. Remove the 2 engine mount nuts.

Fig. 166: Locating Engine Mount Nuts

Courtesy of FORD MOTOR CO.

51. Remove the 3 bolts and the engine mount.

Fig. 167: Locating Engine Mount And Bolts

Courtesy of FORD MOTOR CO.

52. Remove the 5 transaxle mount nuts and the transaxle mount plate.

Fig. 168: Locating Transaxle Mount Nuts

Courtesy of FORD MOTOR CO.

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53. Lower the engine and transaxle assembly from the vehicle.
54. Remove the nut for the HO2S and CMS wire connector bracket.

Fig. 169: Locating HO2S And CMS Wire Connector Bracket Nut
Courtesy of FORD MOTOR CO.

55. Remove the nut and position the HO2S and CMS wire connector bracket aside.

Fig. 170: Locating HO2S And CMS Wire Connector Bracket And Nut
Courtesy of FORD MOTOR CO.

56. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.

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Fig. 171: Locating Output Shaft Speed Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

57. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.

Fig. 172: Locating Turbine Shaft Speed Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

58. Disconnect the 2 transaxle electrical connectors.

Fig. 173: Locating Transaxle Electrical Connectors

Courtesy of FORD MOTOR CO.

59. Disconnect the A/C compressor electrical connector.

Fig. 174: Locating A/C Compressor Electrical Connector

Courtesy of FORD MOTOR CO.

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60. Disconnect the Power Steering Pressure (PSP) switch electrical connector.

Fig. 175: Locating Power Steering Pressure Switch Electrical Connector

Courtesy of FORD MOTOR CO.

61. Detach the wiring harness pin-type retainer from the intake manifold.

Fig. 176: Locating Wiring Harness Pin-Type Retainer From Intake Manifold
Courtesy of FORD MOTOR CO.

62. Detach the 2 Crankshaft Position (CKP) sensor wire harness retainers.

Fig. 177: Locating Crankshaft Position (CKP) Sensor Wire Harness Retainers
Courtesy of FORD MOTOR CO.

63. Disconnect the CKP sensor electrical connector.

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Fig. 178: Locating CKP Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

64. Detach the starter wire harness retainer from the starter motor stud bolt.

Fig. 179: Locating Starter Wire Harness Retainer Of Starter Motor Stud Bolt
Courtesy of FORD MOTOR CO.

65. Remove the nut from the starter motor stud bolt and remove the power steering tube bracket.

Fig. 180: Locating Starter Motor Stud Bolt And Power Steering Tube Bracket
Courtesy of FORD MOTOR CO.

66. Remove the bolt and the engine ground wire.

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Fig. 181: Locating Engine Ground Wire Bolt

Courtesy of FORD MOTOR CO.

67. Remove the nut from the A/C compressor stud bolt and remove the power steering tube bracket.

Fig. 182: Locating A/C Compressor Stud Bolt And Nut

Courtesy of FORD MOTOR CO.

68. Remove the 2 power steering tubes and the wiring harness as an assembly.

Fig. 183: Locating Power Steering Tubes And Wiring Harness

Courtesy of FORD MOTOR CO.

69. Remove the 2 nuts and disconnect the starter motor electrical terminals.

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Fig. 184: Locating Starter Motor Electrical Terminals Nuts

Courtesy of FORD MOTOR CO.

70. Remove the bolt, stud bolt and the starter.

Fig. 185: Locating Starter Stud Bolt And Bolt

Courtesy of FORD MOTOR CO.

71. Remove the starter isolator.

Fig. 186: Locating Starter Isolator

Courtesy of FORD MOTOR CO.

NOTE: Mark one stud and the flexplate for assembly reference.

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Fig. 187: Locating Torque Converter Nut

Courtesy of FORD MOTOR CO.

72. Remove the 4 torque converter nuts.

NOTE: Lower the engine to within a few inches of the floor.

Fig. 188: Raising Engine

Courtesy of FORD MOTOR CO.

73. Using the Floor Crane, Engine Lifting Bracket and Spreader Bar, remove the engine and transaxle
assembly from the lift table.
74. Remove the 4 bellhousing-to-engine bolts and the one stud bolt and separate the engine and transmission.
75. Install the Torque Converter Retainer, to prevent damage to the torque converter.

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Fig. 189: Identifying Torque Converter Retainer

Courtesy of FORD MOTOR CO.

DISASSEMBLY
ENGINE

SPECIAL TOOLS

Alignment Plate, Camshaft

303-465 (T94P-6256-CH)

Engine Stand
014-00232 or equivalent

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2, 200# Floor Crane, Fold Away

300-OTC1819E

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Holding Tool, Crankshaft Damper

303-1416

Holding Tool, Flywheel

303-103 (T74P-6375-A)

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Installer, Connecting Rod

303-462 (T94P-6136-AH)

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Remover, Oil Seal

303-409 (T92C-6700-CH)

Spreader Bar
303-D089 (D93P-6001-A3) or equivalent

Timing Peg, Crankshaft TDC

303-507

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MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® Metal Surface Prep
-
ZC-31-A
Motorcraft® Silicone Gasket Remover
-
ZC-30

NOTE: 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, otherwise
severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. 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: Due to the precision fit and timing of the balancer shaft assembly, it cannot be
removed from the engine block.

NOTE: For additional information, refer to the exploded view under the ASSEMBLY

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procedure .

1. Install the Flywheel Holding Tool and remove the flywheel or flexplate.

Fig. 190: Identifying Flywheel Holding Tool On Flywheel

Courtesy of FORD MOTOR CO.

2. Mount the engine on a suitable engine stand.

3. Loosen the bolt and remove the accessory drivebelt idler pulley.

Fig. 191: Locating Accessory Drive Belt Idler Pulley And Bolt
Courtesy of FORD MOTOR CO.

4. Remove the 3 bolts and the coolant pump pulley.

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Fig. 192: Locating Coolant Pump Pulley Bolts

Courtesy of FORD MOTOR CO.

5. Remove the 3 bolts and the coolant pump.

Fig. 193: Locating Coolant Pump And Bolts

Courtesy of FORD MOTOR CO.

6. Disconnect the oil cooler hose and lower radiator hose from the thermostat housing.

Fig. 194: Locating Oil Cooler Hose And Lower Radiator Hose From Thermostat Housing
Courtesy of FORD MOTOR CO.

7. Disconnect the EGR valve coolant hose.

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Fig. 195: Locating Coolant Hose Of EGR Valve

Courtesy of FORD MOTOR CO.

8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.

Fig. 196: Locating Engine Oil Pressure Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

9. Disconnect the oil cooler hoses.

Fig. 197: Locating Oil Cooler Hoses

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Courtesy of FORD MOTOR CO.

NOTE: A new oil cooler must be installed or severe damage to the engine can
occur.

10. Remove the bolt and the oil cooler.

l Discard the oil cooler.

Fig. 198: Locating Oil Cooler And Bolt

Courtesy of FORD MOTOR CO.

11. Remove the oil filter, 4 bolts and the oil filter adapter.
l Discard the oil filter and gasket.

Fig. 199: Locating Oil Filter And Bolts

Courtesy of FORD MOTOR CO.

12. Disconnect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.

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Fig. 200: Locating Coil-On-Plug And Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.

13. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical
connector.

Fig. 201: Locating Cylinder Head Temperature Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

14. Detach the generator wiring harness retainer from the valve cover stud.

Fig. 202: Locating Generator Wiring Harness Retainer From Valve Cover Stud
Courtesy of FORD MOTOR CO.

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15. Disconnect the 4 fuel injector electrical connectors and detach the 5 wiring harness retainers from valve
cover stud bolts and intake manifold.

Fig. 203: Locating Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

16. Remove the 2 bolts and the fuel rail with the fuel injectors.

Fig. 204: Locating Fuel Rail Bolts

Courtesy of FORD MOTOR CO.

17. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.

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Fig. 205: Locating Knock Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.

18. Disconnect the throttle control electrical connector.

Fig. 206: Locating Throttle Control Electrical Connector

Courtesy of FORD MOTOR CO.

19. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
l Detach the 3 wiring harness retainers from the intake manifold.

Fig. 207: Locating Wiring Harness Retainers From Intake Manifold

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Courtesy of FORD MOTOR CO.

20. Disconnect the EGR valve electrical connector.

Fig. 208: Locating EGR Valve Electrical Connector

Courtesy of FORD MOTOR CO.

21. Remove the lower intake manifold bolt.

Fig. 209: Identifying Lower Intake Manifold Bolt

Courtesy of FORD MOTOR CO.

22. Remove the bolt and the oil level indicator tube.
l Discard the O-ring seal.

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Fig. 210: Locating Oil Level Indicator Tube Bolt

Courtesy of FORD MOTOR CO.

NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also
retain a crash bracket to the intake manifold. The 2 bolts are equipped with
an attachment feature that allows them to be loosened but remain attached
to the intake manifold. Do not attempt to remove the 2 bolts or the crash
bracket from the intake manifold.

Fig. 211: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

23. Loosen the 2 intake manifold bolts.

24. Remove the 5 intake manifold bolts.

Fig. 212: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

NOTE: 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.

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25. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
l Remove the intake manifold.

Fig. 213: Locating PCV Hose Connector

Courtesy of FORD MOTOR CO.

26. Remove the EGR tube.

Fig. 214: Identifying Exhaust Gas Recirculation Tube

Courtesy of FORD MOTOR CO.

27. Remove the radio interference capacitor bracket bolt and position the bracket aside.

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Fig. 215: Locating Radio Interference Capacitor Bracket With Bolt

Courtesy of FORD MOTOR CO.

28. Disconnect the coolant bypass hose.

Fig. 216: Locating Coolant Bypass Hose

Courtesy of FORD MOTOR CO.

29. Remove the 4 bolts and the coolant outlet.

Fig. 217: Locating Coolant Outlet Bolts

Courtesy of FORD MOTOR CO.

30. Disconnect the coolant bypass hose.

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Fig. 218: Locating Coolant Bypass Hose

Courtesy of FORD MOTOR CO.

31. Remove the 3 bolts, thermostat housing and thermostat.

Fig. 219: Locating Thermostat Housing And Bolts

Courtesy of FORD MOTOR CO.

32. Remove the 2 bolts, stud bolt and the A/C compressor.

Fig. 220: Locating A/C Compressor, Stud Bolts And Bolts

Courtesy of FORD MOTOR CO.

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33. Remove the bolt and the KS.

Fig. 221: Locating Bolt And Knock Sensor

Courtesy of FORD MOTOR CO.

34. Remove the 8 bolts and the crankcase vent oil separator.

Fig. 222: Locating Crankcase Vent Oil Separator Mounting Bolts

Courtesy of FORD MOTOR CO.

35. Remove the 3 bolts and the intermediate shaft bracket.

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Fig. 223: Locating Intermediate Shaft Bracket And Bolts

Courtesy of FORD MOTOR CO.

36. Remove the 4 bolts and the ignition coil-on-plugs.

Fig. 224: Locating Ignition Coil-On-Plug Bolts

Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools when removing or installing the spark plugs, damage
can occur to the cylinder head or spark plug.

Fig. 225: Locating Cylinder Head Temperature Sensor And Spark Plug
Courtesy of FORD MOTOR CO.

37. Remove the spark plugs and the CHT sensor.

38. Remove the bolts and the valve cover.

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Fig. 226: Locating Valve Cover Bolts

Courtesy of FORD MOTOR CO.

NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in
damage to the engine. Turn the engine in the normal direction of rotation
only.

39. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead
Center (TDC).
l The hole in the crankshaft pulley should be in the 6 o'clock position.

Fig. 227: Turning Crankshaft Clockwise To Position No. 1 Piston At Top Dead Center
Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this
tool to prevent engine rotation can result in engine damage.

NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate
cannot be installed, rotate the crankshaft one complete revolution
clockwise to correctly position the camshafts.

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Fig. 228: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

40. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
41. Remove the engine plug bolt.

Fig. 229: Locating Engine Plug Bolt

Courtesy of FORD MOTOR CO.

NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it
from turning past TDC. However, the crankshaft can still be rotated in the
counterclockwise direction. The crankshaft must remain at the TDC
position during disassembly.

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Fig. 230: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

42. Install the Crankshaft TDC Timing Peg.

NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during
removal of the pulley bolt or damage to the engine can occur. Therefore,
the crankshaft pulley must be held in place with the Crankshaft Damper
Holding Tool, and the bolt should be removed using an air impact wrench
(1/2-in drive minimum).

NOTE: The crankshaft sprocket diamond washer may come off with the
crankshaft pulley. The diamond washer must be replaced. Remove and
discard the diamond washer. If the diamond washer is not installed,
engine damage may occur.

43. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft
pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
l Remove and discard the crankshaft pulley bolt and washer.

l Remove the crankshaft pulley.

l Remove the diamond washer and discard.

Fig. 231: Locating Crankshaft Pulley Bolt And Washer

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Courtesy of FORD MOTOR CO.

NOTE: Use care not to damage the engine front cover or the crankshaft when
removing the seal.

Fig. 232: Removing Crankshaft Front Oil Seal Using Oil Seal Remover
Courtesy of FORD MOTOR CO.

44. Using the Oil Seal Remover, remove the crankshaft front seal.
45. Remove the 2 bolts and the CKP sensor.

Fig. 233: Locating CKP Sensor

Courtesy of FORD MOTOR CO.

46. Remove the 22 bolts and the engine front cover.

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Fig. 234: Locating Engine Front Cover Bolts

Courtesy of FORD MOTOR CO.

47. Compress the timing chain tensioner in the following sequence.

1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing
the timing chain arm toward the tensioner.
3. Insert a paper clip into the hole to retain the tensioner.

Fig. 235: Compressing Timing Chain Tensioner Using Small Pick

Courtesy of FORD MOTOR CO.

48. Remove the 2 bolts and the timing chain tensioner.

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Fig. 236: Locating Timing Chain Tensioner Bolts

Courtesy of FORD MOTOR CO.

49. Remove the RH timing chain guide.

Fig. 237: Locating RH Timing Chain Guide

Courtesy of FORD MOTOR CO.

50. Remove the timing chain.

Fig. 238: Locating Timing Chain

Courtesy of FORD MOTOR CO.

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51. Remove the 2 bolts and the LH timing chain guide.

Fig. 239: Locating LH Timing Chain Guide Bolts

Courtesy of FORD MOTOR CO.

NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation.
Damage to the tool or the camshaft can occur.

Fig. 240: Locating Camshaft Drive Gear And Bolt

Courtesy of FORD MOTOR CO.

52. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
53. Remove the oil pump drive chain tensioner.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the 2 shoulder bolts.

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Fig. 241: Identifying Oil Pump Chain Drive Tensioner And Shoulder Bolts
Courtesy of FORD MOTOR CO.

NOTE: Remove and discard the crankshaft sprocket diamond washer located
behind the crankshaft sprocket.

NOTE: The oil pump chain sprocket must be held in place.

54. Remove the oil pump chain and sprockets.

1. Remove the bolt.
2. Remove the chain and sprockets.

Fig. 242: Identifying Oil Pump Chain And Sprockets

Courtesy of FORD MOTOR CO.

55. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.

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Fig. 243: Locating Camshaft Lobe Position

Courtesy of FORD MOTOR CO.

NOTE: Failure to follow the camshaft loosening procedure can result in damage
to the camshafts.

NOTE: Mark the location and orientation of each camshaft bearing cap.

56. Remove the camshafts from the engine.

l Loosen the camshaft bearing bolts in the sequence shown in illustration, one turn at a time. Repeat
until all the tension is released.
l Remove the camshaft bearing caps.

l Remove the camshafts.

Fig. 244: Identifying Camshaft Bearing Cap Bolts Loosening Sequence

Courtesy of FORD MOTOR CO.

NOTE: If the camshafts and valve tappets are to be reused, mark the location of
the valve tappets to make sure they are assembled in their original
positions.

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57. Remove the valve tappets.

NOTE: The number on the valve tappets only reflects the digits that follow the
decimal. For example, a tappet with the number 0.650 has the thickness of
3.650 mm.

58. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .
59. Remove the cylinder head.
l Remove and discard the 10 cylinder head bolts.

l Remove the cylinder head.

l Remove and discard the cylinder head gasket.

Fig. 245: Locating Cylinder Head Bolts

Courtesy of FORD MOTOR CO.

60. Remove the cylinder head alignment dowels.

Fig. 246: Locating Cylinder Head Alignment Dowels

Courtesy of FORD MOTOR CO.

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NOTE: 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 that make leak paths. Use a plastic scraping tool to remove all
traces of the head gasket.

NOTE: Observe all warnings and cautions and follow all application directions
contained on the packaging of the silicone gasket remover and the metal
surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be
used to clean and prepare the surfaces.

61. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block
in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket
remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and
to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some
staining of the metal surfaces is normal.
62. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and
the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION .
63. Remove the 13 bolts and the oil pan.

Fig. 247: Locating Oil Pan Bolt

Courtesy of FORD MOTOR CO.

64. Remove the 6 bolts and the crankshaft rear seal with retainer plate.

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Fig. 248: Locating Crankshaft Rear Seal Bolts

Courtesy of FORD MOTOR CO.

65. Remove the 2 bolts, oil pump pickup tube and gasket.
l Discard the gasket.

Fig. 249: Locating Bolts, Oil Pump Pickup Tube And Gasket
Courtesy of FORD MOTOR CO.

66. Remove the 4 bolts and the oil pump.

Fig. 250: Locating Oil Pump Assembly Bolts

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Courtesy of FORD MOTOR CO.

67. Remove the Crankshaft TDC Timing Peg.

Fig. 251: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

68. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or
carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's
instructions.

NOTE: Clearly mark the connecting rods, connecting rod caps and connecting
rod bearings in numerical order for correct orientation for reassembly.

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Fig. 252: Locating Connecting Rod Cap Bolts And Cap

Courtesy of FORD MOTOR CO.

69. Remove the connecting rod cap bolts and cap.

NOTE: Do not scratch the cylinder walls or crankshaft journals with the
connecting rod.

70. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
l Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.

Fig. 253: Removing Piston/Rod Assembly From Engine Block Using Connecting Rod Installer
Courtesy of FORD MOTOR CO.

71. Remove the bolts in the sequence shown in illustration.

l Remove the main bearing beam.

l Discard the bolts.

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Fig. 254: Identifying Crankshaft Cap Bolts Sequence

Courtesy of FORD MOTOR CO.

72. Remove the crankshaft from the engine block.

Fig. 255: Locating Crankshaft Of Engine Block

Courtesy of FORD MOTOR CO.

NOTE: If the main bearings are being reused, mark them in order for correct
orientation and reassembly.

Fig. 256: Locating Crankshaft Main Bearings

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Courtesy of FORD MOTOR CO.

73. Remove the main bearings from the main bearing beam.

NOTE: If the main bearings are being reused, mark them in order for correct
orientation and reassembly.

NOTE: The center bulkhead has the thrust bearing.

Fig. 257: Locating Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

74. Remove the main bearings from the cylinder block.

NOTE: If the oil squirters are being reused, mark them in order for correct
location during reassembly.

NOTE: The front bulkhead does not have an oil squirter.

Fig. 258: Locating Oil Squirters

Courtesy of FORD MOTOR CO.

75. Remove the 4 oil squirters.

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76. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information,
refer to ENGINE SYSTEM - GENERAL INFORMATION .

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

CYLINDER HEAD

SPECIAL TOOLS

Compressor, Valve Spring

303-300 (T87C-6565-A)

Compressor, Valve Spring

303-350 (T89P-6565-A)

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Compressor, Valve Spring

303-472 (T94P-6565-AH)

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Installer, Valve Stem Oil Seal

303-470 (T94P-6510-CH)

Remover, Valve Stem Oil Seal

303-468 (T94P-6510-AH)

Slide Hammer
307-005 (T59L-100-B)

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MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Multi-Purpose Grease
ESB-M1C93-B
Motorcraft® XL-5 (aerosol) and/or CRC® SL3151

Fig. 259: Exploded View Of Cylinder Head

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 W500015 Coolant outlet bolt (4 required)
2 8K556 Coolant outlet
3 8255 Coolant outlet gasket
4 W500225 EGR valve bolt (2 required)

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5 9D475 EGR valve

6 9D476 EGR valve gasket
7 6G004 Cylinder Head Temperature (CHT) sensor
8 6518 Valve collet (16 required)
9 6514 Valve spring retainer (16 required)
10 6513 Valve spring (16 required)
11 6A517 Valve seal (16 required)
12 6505 Intake valve (8 required)
13 6507 Exhaust valve (8 required)
14 9E470 EGR tube
15 6049 Cylinder head

Disassembly

NOTE: If the components are to be reinstalled, mark the location of the components
removed, they must be installed in the same location.

NOTE: One lifting eye shown in illustration, other lifting eye similar.

Fig. 260: Locating Lifting Eyes And Bolts

Courtesy of FORD MOTOR CO.

1. Remove the bolts and the 2 lifting eyes.

2. Remove the 4 bolts and the coolant outlet.
l Discard the gasket.

3. Remove the 2 bolts and the EGR valve.

l Discard the gasket.

4. Remove the Cylinder Head Temperature (CHT) sensor.

5. Remove the EGR tube.

NOTE: Only use hand tools when removing or installing the spark plugs, or

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damage can occur to the cylinder head or spark plug.

NOTE: Use compressed air to remove any foreign material in the spark plug well
before removing the spark plugs.

6. Remove the spark plugs.

NOTE: Use a small screwdriver and multi-purpose grease to remove the valve
collets.

Fig. 261: Compressing Valve Spring

Courtesy of FORD MOTOR CO.

7. Using the Valve Spring Compressors, compress the valve spring and remove the valve spring collets, the
valve spring retainers and the valve springs.
8. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information,
refer to ENGINE SYSTEM - GENERAL INFORMATION .

NOTE: Note the location of the valves if they are to be reused.

NOTE: Mark each valve if the original valves are to be used.

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Fig. 262: Removing Valves

Courtesy of FORD MOTOR CO.

9. Remove the valves.

10. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seals.

Fig. 263: Installing Valve Seal Using Valve Stem Oil Seal Installer
Courtesy of FORD MOTOR CO.

11. Inspect the valves. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION . Install new parts, as necessary.

Assembly

NOTE: If installing the original valves, make sure the valves are installed in the
same position from which they were removed. Coat the valve stems with
clean engine oil.

Fig. 264: Installing Valves

Courtesy of FORD MOTOR CO.

1. Install the valves.

NOTE: Use the protector provided with the replacement kit to prevent damage to
the valve seals.

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Fig. 265: Installing Valve Seal Using Valve Stem Oil Seal Installer
Courtesy of FORD MOTOR CO.

2. Lubricate the valve stems and guides with clean engine oil and, using the Valve Stem Oil Seal Installer,
install the valve seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.

NOTE: Use a small screwdriver and multi-purpose grease to install the valve
collets.

Fig. 266: Compressing Valve Spring

Courtesy of FORD MOTOR CO.

4. Using the Valve Spring Compressors, compress the valve spring and install the valve collets.

NOTE: Only use hand tools when removing or installing the spark plugs, or
damage can occur to the cylinder head or spark plug.

5. Install the spark plugs.

l Tighten to 12 Nm (106 lb-in).

6. Install the EGR tube.

l Tighten to 55 Nm (41 lb-ft).

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7. Install the CHT sensor.

l Tighten to 12 Nm (106 lb-in).

8. Using a new gasket, install the EGR valve, and the 2 bolts.
l Tighten to 20 Nm (177 lb-in).

9. Using a new gasket, install the coolant outlet and the 4 bolts.
l Tighten to 10 Nm (89 lb-in).

NOTE: One lifting eye shown in illustration, other lifting eye similar.

10. Install the 2 lifting eyes and the bolts.

l Tighten to 45 Nm (33 lb-ft).

Fig. 267: Locating Lifting Eyes And Bolts

Courtesy of FORD MOTOR CO.

PISTON

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

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Fig. 268: Exploded View Of Pistion

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6150 Piston compression upper ring
2 6152 Piston compression lower ring
3 6159 Piston oil control upper segment ring
4 6161 Piston oil control spacer
5 6159 Piston oil control lower segment ring
6 6140 Piston pin retainer
7 6140 Piston pin retainer
8 6135 Piston pin
9 6200 Connecting rod
10 6110 Piston

Disassembly

1. Remove the piston rings from the piston.

l Discard the piston rings.

2. Remove the 2 piston pin retainers and the piston pin.

NOTE: If the piston and connecting rod are to be reinstalled, they must be
assembled in the same orientation. Mark the piston orientation to the
connecting rod for reassembly.

3. Separate the piston from the connecting rod.

4. Clean and inspect the piston and connecting rod. For additional information, refer to ENGINE SYSTEM
- GENERAL INFORMATION .

Assembly

NOTE: The arrow on the top of the piston points towards the front of the engine.

1. Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.

NOTE: The piston compression upper and lower ring should be installed with the
paint mark on the outside diameter circumference of the ring to be
positioned on the right side of the ring gap. The lower compression ring
needs to be installed with the undercut side downward.

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NOTE: The upper and lower compression ring gaps are not controlled for
installation.

6. Install the piston rings onto the piston as shown in illustration.

1. Piston pin
2. Upper oil control ring gap location
3. Lower oil control ring gap location
4. Center line of the piston pin bore and the expander gap

Fig. 269: Identifying Piston Rings Installation Dimensions

Courtesy of FORD MOTOR CO.

ASSEMBLY
ENGINE

SPECIAL TOOLS

Aligner, Crankshaft Sensor

303-1417

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Alignment Plate, Camshaft

303-465 (T94P-6256-CH)

Compressor, Piston Ring

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303-D032 (D81L-6002-C)

Dial Indicator Gauge with Holding Fixture

100-002 (TOOL-4201-C)

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2, 200# Floor Crane, Fold Away

300-OTC1819E or equivalent

Holding Tool, Crankshaft Damper

303-1416

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Installer, Camshaft Front Oil Seal

303-096 (T74P-6150-A)

Installer, Connecting Rod

303-462 (TOOL-6136-AH)

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Installer, Crankshaft Rear Main Oil Seal

303-328 (T88P-6701-B1)

Spreader Bar
303-D089 (D93P-6001-A3) or equivalent

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Timing Peg, Crankshaft TDC

303-507

GENERAL EQUIPMENT
6 mm x 18 mm bolt

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft® Metal Surface Prep
-
ZC-31-A
Motorcraft® Orange Antifreeze/Coolant Concentrated WSS-M97B44-
VC-3-B (US); CVC-3-B2 (Canada) D
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Silicone Brake Caliper Grease and Dielectric Compound
ESE-M1C171-A
XG-3-A
Silicone Gasket and Sealant WSE-M4G323-
TA-30 A4

Lower Engine Block (View 1)

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Fig. 270: Exploded View Of Lower Engine Block (1)

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6010 Cylinder block
2 6K318 Crankshaft rear oil seal and retainer
3 6477 Flywheel/flexplate
4 6675 Oil pan
5 6714 Oil filter
6 6884 Oil filter adapter
7 9278 Engine Oil Pressure (EOP) sensor
8 6A642 Oil cooler
9 6A636 Oil filter adapter gasket
10 6A785 Crankcase vent oil separator
11 8575 Thermostat assembly
12 6622 Oil pump screen and pickup tube

Lower Engine Block (View 2)

Fig. 271: Exploded View Of Lower Engine Block (2)

Courtesy of FORD MOTOR CO.

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Item Part Number Description

1 6161 Piston oil control spacer (4 required)
2 6150 Piston compression upper ring (4 required)
3 6152 Piston compression lower ring (4 required)
4 6159 Piston oil control upper segment ring (4 required)
5 6159 Piston oil control lower segment ring (4 required)
6 6140 Piston pin retainer (8 required)
7 6135 Piston pin (4 required)
8 6200 Connecting rod (4 required)
9 6211 Connecting rod upper bearing (4 required)
10 6110 Piston (4 required)
11 6211 Connecting rod lower bearing (4 required)
12 6210 Connecting rod cap (4 required)
13 6010 Cylinder block
14 6333 Cylinder block crankshaft main bearing (5 required)
15 6303 Crankshaft
16 6333 Crankshaft main bearing beam bearing (5 required)
17 6F098 Main bearing beam

Front Engine Block

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Fig. 272: Exploded View Of Front Engine Block

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 6C301 Accessory drive belt
2 6A340 Crankshaft pulley bolt
3 6316 Crankshaft damper

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4 6700 Crankshaft front seal

5 6C315 Crankshaft Position (CKP) sensor
6 10300 Generator
7 3A696 Power steering pump
8 8501 Coolant pump and pulley
9 19A216 Drive belt pulley idler
10 6A228 Drive belt tensioner
11 6019 Engine front cover
12 6378 Diamond washer
13 6306 Crankshaft sprocket
14 6378 Diamond washer
15 6K254 Timing chain tensioner
16 6K255 Timing chain tensioner arm
17 6268 Timing chain
18 6K297 Timing chain guide
19 6A895 Oil pump chain
20 6C271 Oil pump chain tensioner
21 6652 Oil pump drive gear
22 6600 Oil pump
23 6010 Cylinder block

Cylinder Head

Fig. 273: Exploded View Of Cylinder Head

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 12A366 Coil-on-plug (4 required)
2 6M293 Valve cover
3 12K073 Camshaft Position (CMP) sensor
4 6766 Oil filler cap

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5 6M293 Valve cover gasket

6 6A284 Camshaft bearing cap
7 6A272 Camshaft (exhaust)
8 6A271 Camshaft (intake)
9 6500 Valve tappet (16 required)
10 6518 Valve spring retainer key (16 required)
11 6514 Valve spring retainer (16 required)
12 6513 Valve spring (16 required)
13 6A517 Valve stem seal (16 required)
14 6G004 Cylinder Head Temperature (CHT) sensor
15 12405 Spark plug (4 required)
16 6065 Cylinder head bolt (10 required)
17 6049 Cylinder head
18 6505 Exhaust valve (8 required)
19 6507 Intake valve (8 required)
20 6051 Head gasket
21 6010 Cylinder block
22 6C251 Camshaft sprocket (2 required)
23 9448 Exhaust manifold gasket
24 9430 Exhaust manifold
25 9N454 Exhaust manifold heat shield

Intake Manifold

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Fig. 274: Exploded View Of Intake Manifold

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 9288 Fuel supply tube
2 8K556 Coolant outlet
3 9D475 EGR valve
4 9E926 Throttle Body (TB)
5 6051 Cylinder head gasket
6 6010 Cylinder block
7 12A699 Knock Sensor (KS)
8 6754 Oil level indicator and tube
9 9424 Intake manifold

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10 9439 Intake manifold gasket

11 6049 Cylinder head
12 9F593 Fuel injector (4 required)
13 9H487 Fuel rail

NOTE: 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, otherwise
severe engine damage can occur.

NOTE: 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. For additional information, refer to
ENGINE SYSTEM - GENERAL INFORMATION .

NOTE: If the oil squirters are being reused, they must be installed in the same
location as marked during disassembly.

NOTE: The front bulkhead does not have an oil squirter.

1. Install the 4 oil squirters.

l Tighten to 4 Nm (35 lb-in).

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Fig. 275: Locating Oil Squirters

Courtesy of FORD MOTOR CO.

2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the
smallest diameter for each journal.

Fig. 276: Identifying Crankshaft Main Bearing Journal Diameter Measuring Directions
Courtesy of FORD MOTOR CO.

3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the
rear face of the engine block.

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Fig. 277: Locating Main Bearing Beam In Engine Block

Courtesy of FORD MOTOR CO.

4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
l Tighten the bolts in the sequence shown in illustration in 3 stages.

l Stage 1: Tighten to 5 Nm (44 lb-in).

l Stage 2: Tighten to 25 Nm (18 lb-ft).

l Stage 3: Tighten an additional 90 degrees.

Fig. 278: Identifying Main Bearing Beam Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

5. Measure each crankshaft block housing main bearing bore diameter.

l Remove the bolts and the main bearing beam.

l Discard the main bearing beam bolts.

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Fig. 279: Identifying Crankshaft Block Housing Main Bearing Bore Diameter
Courtesy of FORD MOTOR CO.

6. Using the chart, select the crankshaft main bearings.

Fig. 280: Crankshaft Main Bearings Chart

Courtesy of FORD MOTOR CO.

NOTE: The rod cap installation must keep the same orientation as marked during
disassembly or engine damage may occur.

7. Using the original connecting rod cap bolts, install the connecting caps and bolts.
l Tighten the bolts in 2 stages.

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Stage 1: Tighten to 29 Nm (21 lb-ft).

l

l Stage 2: Tighten an additional 90 degrees.

8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each
connecting rod.
l Remove the bolts and the connecting rod cap.

l Discard the connecting rod cap bolts.

Fig. 281: Identifying Connecting Rod Large End Bore Measuring Directions
Courtesy of FORD MOTOR CO.

9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record
the smallest measurement for each connecting rod journal.

Fig. 282: Locating Crankshaft Connecting Rod Bearing Journal Diameters In Measuring
Directions
Courtesy of FORD MOTOR CO.

10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

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Fig. 283: Connecting Rod Bearings Chart

Courtesy of FORD MOTOR CO.

NOTE: Before assembling the cylinder block, all sealing surfaces must be free of
chips, dirt, paint and foreign material. Also, make sure the coolant and oil
passages are clear.

NOTE: If reusing the crankshaft main bearings, install them in their original
positions and orientation as noted during disassembly.

NOTE: The center bulkhead is the thrust bearing.

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Fig. 284: Locating Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

11. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main
bearings in the cylinder block.

NOTE: If reusing the crankshaft main bearings, install them in their original
positions and orientation as noted during disassembly.

Fig. 285: Locating Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in
the main bearing beam.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.

Fig. 286: Locating Crankshaft Of Engine Block

Courtesy of FORD MOTOR CO.

15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown in illustration) with clean engine oil.

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Fig. 287: Locating Main Bearing Beam Lubrication Area

Courtesy of FORD MOTOR CO.

16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position
the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face
of the engine block.

Fig. 288: Locating Main Bearing Beam In Engine Block

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads
with clean engine oil.

NOTE: Position the crankshaft to the rear of the cylinder block, then position the
crankshaft to the front of the cylinder block before tightening the main
bearing beam bolts.

17. Install and tighten the 10 main bearing beam bolts.

l Tighten the bolts in the sequence shown in 3 stages.

l Stage 1: Tighten to 5 Nm (44 lb-in).

l Stage 2: Tighten to 25 Nm (18 lb-ft).

l Stage 3: Tighten an additional 90 degrees.

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Fig. 289: Identifying Main Bearing Beam Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
l Position the crankshaft to the rear of the cylinder block.

l Zero the Dial Indicator Gauge with Holding Fixture.

l Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.

l Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play
exceeds the specified range, install new parts as necessary.

Fig. 290: Measuring Crankshaft End Play Using Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.

NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the
connecting rod. Push the piston down until the connecting rod bearing
seats on the crankshaft journal.

NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire
cylinder bores with clean engine oil.

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

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19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod
assemblies.
l When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60
degrees apart from each other and a minimum of 90 degrees from the expander gap.
l The position of the upper and lower compression ring gaps are not controlled for installation.

Fig. 291: Identifying Piston Ring Compressor And Connecting Rod Installer
Courtesy of FORD MOTOR CO.

NOTE: The rod cap installation must keep the same orientation as marked during
disassembly or engine damage may occur.

NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders
1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install
connecting rod caps and bolts on connecting rods for cylinders 2 and 3
and tighten.

NOTE: After installation of each connecting rod cap, rotate the crankshaft to
verify smooth operation.

20. Install the connecting rod caps and bolts.

l Tighten the bolts in 2 stages.

l Stage 1: Tighten to 29 Nm (21 lb-ft).

l Stage 2: Tighten an additional 90 degrees.

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Fig. 292: Locating Connecting Rod Caps And Bolts

Courtesy of FORD MOTOR CO.

NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in
damage to the engine. Turn the engine in the normal direction of rotation
only.

21. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).

NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it
from turning past TDC. However, the crankshaft can still be rotated in the
counterclockwise direction. The crankshaft must remain at the TDC
position until the timing drive components and crankshaft pulley are
installed.

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Fig. 293: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

22. Install the Crankshaft TDC Timing Peg.

NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface
prep.

23. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages.
l Stage 1: Tighten to 10 Nm (89 lb-in).

l Stage 2: Tighten to 20 Nm (177 lb-in).

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Fig. 294: Identifying Oil Pump Assembly Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

24. Using a new oil pump pickup tube gasket, install the pickup tube and bolts.
l Tighten to 10 Nm (89 lb-in).

Fig. 295: Locating Bolts, Oil Pump Pickup Tube And Gasket
Courtesy of FORD MOTOR CO.

25. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear seal.

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Fig. 296: Identifying Crankshaft Rear Main Oil Seal Installer

Courtesy of FORD MOTOR CO.

26. Tighten the 6 crankshaft rear seal with retainer plate bolts in the sequence shown in illustration.
l Tighten to 10 Nm (89 lb-in).

Fig. 297: Identifying Crankshaft Rear Oil Seal Retainer Plate Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.

NOTE: 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. Use a plastic scraping tool to remove
traces of sealant.

27. Clean and inspect all mating surfaces.

NOTE: If the oil pan is not secured within 4 minutes of sealant application, the
sealant must be removed and the sealing area cleaned with metal surface
prep. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil
leakage.

Fig. 298: Locating Oil Pan Silicone Gasket And Sealant Bead Applying Area

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Courtesy of FORD MOTOR CO.

28. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil
pan-to-engine front cover mating surface.
29. Install the oil pan. Install the 2 oil pan bolts finger-tight.

Fig. 299: Locating Oil Pan Bolts

Courtesy of FORD MOTOR CO.

30. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the
engine block.

Fig. 300: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block Using
Straightedge
Courtesy of FORD MOTOR CO.

31. Install the remaining 13 oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration to
25 Nm (18 lb-ft).

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Fig. 301: Identifying Oil Pan Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

32. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.

Fig. 302: Locating Cylinder Head Alignment Dowels

Courtesy of FORD MOTOR CO.

33. Apply silicone gasket and sealant to the locations shown in illustration.

Fig. 303: Locating Sealant Applying Area On Cylinder Block

Courtesy of FORD MOTOR CO.

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34. Install a new cylinder head gasket.

Fig. 304: Locating Cylinder Head Gasket

Courtesy of FORD MOTOR CO.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New
cylinder head bolts must be installed.

35. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages.
l Stage 1: Tighten to 5 Nm (44 lb-in).

l Stage 2: Tighten to 15 Nm (133 lb-in).

l Stage 3: Tighten to 45 Nm (33 lb-ft).

l Stage 4: Turn 90 degrees.

l Stage 5: Turn an additional 90 degrees.

Fig. 305: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

NOTE: If the camshafts and valve tappets are to be reused, make sure they are
assembled in their original positions.

NOTE: Coat the valve tappets with clean engine oil.

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36. Install the valve tappets.

NOTE: Install the camshafts with the alignment slots in the camshafts lined up so
the Camshaft Alignment Plate can be installed without rotating the
camshafts. Make sure the lobes on the No. 1 cylinder are in the same
position as noted in the disassembly procedure. Rotating the camshafts
when the timing chain is removed, or installing the camshafts 180 degrees
out of position, can cause severe damage to the valves and pistons.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.

37. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps
in the sequence shown in 3 stages:
l Stage 1: Tighten one turn at a time until tight.

l Stage 2: Tighten to 7 Nm (62 lb-in).

l Stage 3: Tighten to 16 Nm (142 lb-in).

Fig. 306: Identifying Camshafts And Bearing Caps Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.

NOTE: Install a new crankshaft sprocket diamond washer on both sides of the
crankshaft sprocket.

38. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump
sprocket.
l The crankshaft sprocket flange must be facing away from the engine block.

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Fig. 307: Locating Crankshaft Sprocket Flange

Courtesy of FORD MOTOR CO.

39. Install the oil pump chain, sprocket and bolt.

l Tighten to 25 Nm (18 lb-ft).

Fig. 308: Locating Oil Pump Chain, Sprocket And Bolt

Courtesy of FORD MOTOR CO.

40. Install the oil pump chain tensioner shoulder bolt.

l Tighten to 10 Nm (89 lb-in).

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Fig. 309: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
Courtesy of FORD MOTOR CO.

41. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
l Tighten to 10 Nm (89 lb-in).

Fig. 310: Locating Oil Pump Chain Tensioner

Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this
tool to prevent engine rotation can result in engine damage.

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Fig. 311: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

42. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
43. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.

Fig. 312: Locating Camshaft Sprockets And Bolts

Courtesy of FORD MOTOR CO.

44. Install the LH timing chain guide and the 2 bolts.

l Tighten to 10 Nm (89 lb-in).

Fig. 313: Locating LH Timing Chain Guide Bolts

Courtesy of FORD MOTOR CO.

45. Install the timing chain.

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Fig. 314: Locating Timing Chain

Courtesy of FORD MOTOR CO.

46. Install the RH timing chain guide.

Fig. 315: Locating RH Timing Chain Guide

Courtesy of FORD MOTOR CO.

NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned
in the compressed position, follow the next 4 steps.

NOTE: Do not compress the ratchet assembly. This will damage the ratchet
assembly.

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Fig. 316: Compressing Timing Chain Tensioner Plunger

Courtesy of FORD MOTOR CO.

47. Using the edge of a vise, compress the timing chain tensioner plunger.
48. Using a small pick, push back and hold the ratchet mechanism.

Fig. 317: Holding Ratchet Mechanism Using Small Pick

Courtesy of FORD MOTOR CO.

49. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

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Fig. 318: Pushing Ratchet Arm Back Into Tensioner Housing

Courtesy of FORD MOTOR CO.

50. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in
during installation.

Fig. 319: Holding Ratchet Assembly Using Paper Clip

Courtesy of FORD MOTOR CO.

51. Install the timing chain tensioner and the 2 bolts.

l Tighten to 10 Nm (89 lb-in).

l Remove the paper clip to release the piston.

Fig. 320: Locating Timing Chain Tensioner And Bolts

Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this
tool to prevent engine rotation can result in engine damage.

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Fig. 321: Locating Camshaft Drive Gear Bolts

Courtesy of FORD MOTOR CO.

52. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts to 72
Nm (53 lb-ft).

NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other
abrasive means to clean sealing surfaces. These tools cause scratches
and gouges which make leak paths.

53. Clean and inspect the mounting surfaces of the engine and the front cover.

NOTE: The engine front cover must be installed and the bolts tightened within 4
minutes of applying the silicone gasket and sealant.

Fig. 322: Locating Bead Of Silicone Gasket And Sealant Applying Area On Front Cover
Courtesy of FORD MOTOR CO.

54. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas.
Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
55. Install the engine front cover. Tighten the 22 bolts in the sequence shown to the following specifications:
l Tighten the 8-mm bolts to 10 Nm (89 lb-in).

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l Tighten the 13-mm bolts to 48 Nm (35 lb-ft).

Fig. 323: Identifying Engine Front Cover Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.

Fig. 324: Installing Crankshaft Front Oil Seal Using Camshaft Front Oil Seal Installer
Courtesy of FORD MOTOR CO.

56. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.

NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

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Fig. 325: Locating Crankshaft Pulley Position

Courtesy of FORD MOTOR CO.

57. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.

NOTE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Fig. 326: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

58. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.

NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during
installation of the pulley bolt or damage to the engine can occur.
Therefore, the crankshaft pulley must be held in place with the Crankshaft
Damper Holding Tool and the bolt should be installed using hand tools
only.

NOTE: Do not reuse the crankshaft pulley bolt.

59. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive
hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:

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l Stage 1: Tighten to 100 Nm (74 lb-ft).

l Stage 2: Tighten an additional 90 degrees (one-fourth turn).

Fig. 327: Locating Crankshaft Pulley Bolt And Washer

Courtesy of FORD MOTOR CO.

60. Remove the 6 mm x 18 mm bolt.

Fig. 328: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

61. Remove the Crankshaft TDC Timing Peg.

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Fig. 329: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

62. Remove the Camshaft Alignment Plate.

Fig. 330: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

63. Turn the crankshaft clockwise one and three-fourths turn.

64. Install the Crankshaft TDC Timing Peg.

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Fig. 331: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

Fig. 332: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

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65. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.

NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

66. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
l If it is not possible to install the bolt, the engine valve timing must be corrected.

Fig. 333: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

67. Install the Camshaft Alignment Plate to check the position of the camshafts.
l If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be
corrected.

Fig. 334: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

68. Remove the Camshaft Alignment Plate.

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Fig. 335: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

69. Install the Crankshaft Position (CKP) sensor and the 2 bolts.
l Do not tighten the bolts at this time.

Fig. 336: Locating CKP Sensor Bolts

Courtesy of FORD MOTOR CO.

70. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
l Tighten the 2 CKP bolts to 7 Nm (62 lb-in).

Fig. 337: Adjusting CKP Sensor Using Crankshaft Sensor Aligner

Courtesy of FORD MOTOR CO.

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71. Remove the 6 mm x 18 mm bolt.

Fig. 338: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

72. Remove the Crankshaft TDC Timing Peg.

Fig. 339: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

73. Install the engine plug bolt.

l Tighten to 20 Nm (177 lb-in).

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Fig. 340: Locating Engine Plug Bolt

Courtesy of FORD MOTOR CO.

NOTE: 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.

74. Clean the valve cover gasket surface with metal surface prep.
75. Apply silicone gasket and sealant to the locations shown in illustration.

Fig. 341: Locating Sealant Applying Area On Valve Cover

Courtesy of FORD MOTOR CO.

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 prep.

76. Install the valve cover.

l Tighten the 14 bolts in the sequence shown to 10 Nm (89 lb-in).

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Fig. 342: Identifying Valve Cover Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools when removing or installing the spark plugs, damage
can occur to the cylinder head or spark plug.

77. Install the Cylinder Head Temperature (CHT) sensor and the spark plugs.
l Tighten the CHT sensor to 12 Nm (106 lb-in).

l Tighten the spark plugs to 12 Nm (106 lb-in).

Fig. 343: Locating Cylinder Head Temperature Sensor And Spark Plug
Courtesy of FORD MOTOR CO.

NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

78. Install the 4 ignition coil-on-plugs and the 4 bolts.

l Tighten to 10 Nm (89 lb-in).

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Fig. 344: Locating Ignition Coil-On-Plug Bolts

Courtesy of FORD MOTOR CO.

79. Install the intermediate shaft bracket and the 3 bolts.

l Tighten to 48 Nm (35 lb-ft).

Fig. 345: Locating Intermediate Shaft Bracket And Bolts

Courtesy of FORD MOTOR CO.

80. Install the crankcase vent oil separator and the 8 bolts.
l Tighten to 10 Nm (89 lb-in).

Fig. 346: Locating Crankcase Vent Oil Separator Mounting Bolts

Courtesy of FORD MOTOR CO.

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NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.

81. Install the KS and the bolt.

l Tighten to 20 Nm (177 lb-in).

Fig. 347: Locating Bolt And Knock Sensor

Courtesy of FORD MOTOR CO.

82. Install the A/C compressor, 2 bolts and the stud bolt.
l Tighten to 25 Nm (18 lb-ft).

Fig. 348: Locating A/C Compressor, Stud Bolts And Bolts

Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if
necessary.

83. Install the thermostat housing and 3 bolts.

l Tighten to 10 Nm (89 lb-in).

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Fig. 349: Locating Thermostat Housing And Bolts

Courtesy of FORD MOTOR CO.

84. Connect the coolant bypass hose.

Fig. 350: Locating Coolant Bypass Hose

Courtesy of FORD MOTOR CO.

85. Using a new gasket, install the coolant outlet and the 4 bolts.
l Tighten to 10 Nm (89 lb-in).

Fig. 351: Locating Coolant Outlet Bolts

Courtesy of FORD MOTOR CO.

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86. Connect the coolant bypass hose.

Fig. 352: Locating Coolant Bypass Hose

Courtesy of FORD MOTOR CO.

87. Install the radio interference capacitor bracket and bolt.

l Tighten to 10 Nm (89 lb-in).

Fig. 353: Locating Radio Interference Capacitor Bracket With Bolt

Courtesy of FORD MOTOR CO.

88. Install the EGR tube.

l Tighten to 55 Nm (41 lb-ft).

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Fig. 354: Identifying Exhaust Gas Recirculation Tube

Courtesy of FORD MOTOR CO.

89. Inspect and install new intake manifold gaskets if necessary.

NOTE: 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.

Fig. 355: Locating PCV Hose Connector

Courtesy of FORD MOTOR CO.

90. Position the intake manifold and connect the PCV hose.

NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also
retain a crash bracket to the intake manifold. The 2 bolts are equipped with
an attachment feature that allows them to be loosened but remain attached
to the intake manifold. Do not attempt to remove the 2 bolts or the crash
bracket from the intake manifold.

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Fig. 356: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

91. Install the intake manifold and hand-tighten the 2 intake manifold bolts.
92. Install the 5 intake manifold mounting bolts.
l Tighten all 7 bolts to 18 Nm (159 lb-in).

Fig. 357: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new O-ring with clean engine oil.

93. Using a new O-ring seal, install the oil level indicator tube assembly and the bolt.
l Tighten to 10 Nm (89 lb-in).

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Fig. 358: Locating Oil Level Indicator Tube Bolt

Courtesy of FORD MOTOR CO.

94. Install the lower intake manifold bolt.

l Tighten to 18 Nm (159 lb-in).

Fig. 359: Identifying Lower Intake Manifold Bolt

Courtesy of FORD MOTOR CO.

95. Connect the EGR valve electrical connector.

Fig. 360: Locating EGR Valve Electrical Connector

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Courtesy of FORD MOTOR CO.

96. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
l Attach the 3 wiring harness retainers to the intake manifold.

Fig. 361: Locating Wiring Harness Retainers To Intake Manifold

Courtesy of FORD MOTOR CO.

97. Connect the throttle control electrical connector.

Fig. 362: Locating Throttle Control Electrical Connector

Courtesy of FORD MOTOR CO.

98. Connect the KS electrical connector and pin-type retainer.

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Fig. 363: Locating Knock Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.

NOTE: 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.

99. Install new fuel injector O-rings.

l Separate the fuel injectors from the fuel rail.

l Remove and discard the fuel injector O-rings.

l Install new O-rings and lubricate with clean engine oil.

l Install the fuel injectors onto the fuel rail.

Fig. 364: Locating Fuel Injector O-Rings

Courtesy of FORD MOTOR CO.

100. Install the fuel rail with the fuel injectors and the 2 bolts.
l Tighten to 25 Nm (18 lb-ft).

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Fig. 365: Locating Fuel Rail Bolts

Courtesy of FORD MOTOR CO.

101. Connect the 4 fuel injector electrical connectors and attach the 4 wiring harness retainers to valve cover
stud bolts and intake manifold.

Fig. 366: Locating Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

102. Attach the wiring harness retainer on the valve cover stud.

Fig. 367: Locating Wiring Harness Retainer On Valve Cover Stud

Courtesy of FORD MOTOR CO.

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103. Position the engine control wiring harness on the engine and connect the CHT sensor and install the
rubber boot.

Fig. 368: Locating Cylinder Head Temperature Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

104. Connect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.

Fig. 369: Locating Coil-On-Plug And Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.

NOTE: Clean the gasket mating surfaces with metal surface prep.

105. Using a new gasket, install the oil filter adapter and the 4 bolts.
l Tighten to 25 Nm (18 lb-ft).

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Fig. 370: Locating Oil Filter Adapter And 4 Bolts

Courtesy of FORD MOTOR CO.

NOTE: A new oil cooler must be installed or severe damage to the engine can
occur.

106. Install a new oil cooler and bolt.

l Tighten to 34 Nm (25 lb-ft).

Fig. 371: Locating Oil Cooler And Bolt

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the oil filter gasket with clean engine with clean engine oil prior
to installation.

107. Install the oil filter.

l Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter
adapter.

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Fig. 372: Locating Oil Filter

Courtesy of FORD MOTOR CO.

108. Connect the oil cooler hoses.

Fig. 373: Locating Oil Cooler Hoses

Courtesy of FORD MOTOR CO.

109. Connect the Engine Oil Pressure (EOP) switch electrical connector.

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Fig. 374: Locating Engine Oil Pressure Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

110. Connect the EGR valve coolant hose.

Fig. 375: Locating Coolant Hose Of EGR Valve

Courtesy of FORD MOTOR CO.

111. Connect the oil cooler hose and lower radiator hose to the thermostat housing.

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Fig. 376: Locating Oil Cooler Hose And Lower Radiator Hose From Thermostat Housing
Courtesy of FORD MOTOR CO.

NOTE: Clean the coolant pump mating surface with metal surface prep.

NOTE: Lubricate the coolant pump O-ring with clean engine coolant.

112. Position the coolant pump and install the 3 bolts.

l Tighten to 10 Nm (89 lb-in).

Fig. 377: Locating Coolant Pump And Bolts

Courtesy of FORD MOTOR CO.

113. Install the coolant pump pulley and 3 bolts.

l Tighten to 20 Nm (177 lb-in).

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Fig. 378: Locating Coolant Pump Pulley Bolts

Courtesy of FORD MOTOR CO.

114. Install the accessory drive belt idler pulley.

l Tighten to 25 Nm (18 lb-ft).

Fig. 379: Locating Accessory Drive Belt Idler Pulley And Bolt
Courtesy of FORD MOTOR CO.

115. Using the Floor Crane and Spreader Bar, remove the engine from the engine stand.
116. Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in 3 stages:
l Stage 1: Tighten to 50 Nm (37 lb-ft).

l Stage 2: Tighten to 80 Nm (50 lb-ft).

l Stage 3: Tighten to 112 Nm (83 lb-ft).

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Fig. 380: Identifying Flexplate Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

INSTALLATION
ENGINE

SPECIAL TOOLS

2, 200# Floor Crane, Fold Away

300-OTC1819E or equivalent

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Lifting Bracket, Engine

303-050 (T70P-6000)

Powertrain Lift
300-OTC1585AE or equivalent

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Spreader Bar
303-D089 (D93P-6001-A3) or equivalent

Adjustable Grip Arm, 1735A

014-00001 or equivalent

MATERIAL SPECIFICATIONS
Item Specification

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Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE
WSS-M2C945-
5W-20 Super Premium Motor Oil (Canada)
A
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Multi-Purpose Grease
ESB-M1C93-B
Motorcraft® XL-5 (aerosol) and/or CRC® SL3151

NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.

1. Check the installation depth of the torque converter.

1. Lay a straightedge on the automatic transaxle flange.
2. Check the installation depth between the transaxle flange and the torque converter centering spigot
for the correct clearance.

Fig. 381: Identifying Depth Between Transaxle Flange And Torque Converter Centering
Spigot
Courtesy of FORD MOTOR CO.

2. Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6
bellhousing-to-engine fasteners.
l Tighten to 48 Nm (35 lb-ft).

3. Using the Floor Crane, Engine Lifting Bracket and Spreader Bar, raise the engine and transaxle assembly
onto the lift table.

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Fig. 382: Raising Engine

Courtesy of FORD MOTOR CO.

4. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine and transaxle assembly to the lift
table.

Fig. 383: Securing Engine To Lift Table Using Powertrain Lift And Adjustable Grip Arm
Courtesy of FORD MOTOR CO.

NOTE: If new parts are not being used, be sure to align the marks on the flexplate
and the stud made during engine removal.

5. Install the 4 torque converter nuts.

l Tighten to 35 Nm (26 lb-ft).

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Fig. 384: Locating Torque Converter Nut

Courtesy of FORD MOTOR CO.

6. Install the starter motor isolator.

Fig. 385: Locating Starter Motor Isolator

Courtesy of FORD MOTOR CO.

7. Install the starter motor, stud bolt and the bolt.

l Install the upper bolt and lower stud bolt finger-tight.

l Tighten the upper bolt to 35 Nm (26 lb-ft).

l Tighten the lower stud bolt to 35 Nm (26 lb-ft).

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Fig. 386: Locating Starter Stud Bolt And Bolt

Courtesy of FORD MOTOR CO.

8. Connect the starter motor electrical terminals and install the 2 nuts.
l Tighten the small nut to 5 Nm (44 lb-in).

l Tighten the large nut to 12 Nm (106 lb-in).

Fig. 387: Locating Starter Motor Electrical Terminals Nuts

Courtesy of FORD MOTOR CO.

9. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.

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Fig. 388: Locating Power Steering Tubes And Wiring Harness

Courtesy of FORD MOTOR CO.

10. Install the power steering tube bracket on the A/C compressor stud bolt and install the nut.
l Tighten to 20 Nm (177 lb-in).

Fig. 389: Locating A/C Compressor Stud Bolt And Nut

Courtesy of FORD MOTOR CO.

11. Install the engine ground wire and the bolt.

l Tighten to 48 Nm (35 lb-ft).

Fig. 390: Locating Engine Ground Wire Bolt

Courtesy of FORD MOTOR CO.

12. Install the power steering tube bracket on the starter motor stud bolt and install the nut.

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l Tighten to 20 Nm (177 lb-in).

Fig. 391: Locating Starter Motor Stud Bolt And Power Steering Tube Bracket
Courtesy of FORD MOTOR CO.

13. Attach the starter wire harness retainer to the starter motor stud bolt.

Fig. 392: Locating Starter Wire Harness Retainer Of Starter Motor Stud Bolt
Courtesy of FORD MOTOR CO.

14. Connect the Crankshaft Position (CKP) sensor electrical connector.

Fig. 393: Locating CKP Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

15. Attach the 2 CKP sensor wire harness retainers.

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Fig. 394: Locating Crankshaft Position (CKP) Sensor Wire Harness Retainers
Courtesy of FORD MOTOR CO.

16. Attach the wire harness pin-type retainer to the intake manifold.

Fig. 395: Locating Wiring Harness Pin-Type Retainer To Intake Manifold

Courtesy of FORD MOTOR CO.

17. Connect the Power Steering Pressure (PSP) switch electrical connector.

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Fig. 396: Locating Power Steering Pressure Switch Electrical Connector

Courtesy of FORD MOTOR CO.

18. Connect the A/C compressor electrical connector.

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Fig. 397: Locating A/C Compressor Electrical Connector

Courtesy of FORD MOTOR CO.

19. Connect the 2 transaxle electrical connectors.

Fig. 398: Locating Transaxle Electrical Connectors

Courtesy of FORD MOTOR CO.

20. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.

Fig. 399: Locating Turbine Shaft Speed Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

21. Connect the Output Shaft Speed (OSS) sensor electrical connector.

Fig. 400: Locating Output Shaft Speed Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

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22. Position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket
and install the nut.
l Tighten to 25 Nm (18 lb-ft).

Fig. 401: Locating HO2S And CMS Wire Connector Bracket And Nut
Courtesy of FORD MOTOR CO.

23. Install the nut for the HO2S and CMS wire connector bracket.
l Tighten to 25 Nm (18 lb-ft).

Fig. 402: Locating HO2S And CMS Wire Connector Bracket Nut
Courtesy of FORD MOTOR CO.

24. Using the lift table, position the engine and transaxle assembly in the vehicle.
25. Install the transaxle mount plate and the 5 nuts.
l Tighten the center nut to 150 Nm (111 lb-ft).

l Tighten the 4 outer nuts to 48 Nm (35 lb-ft).

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Fig. 403: Locating Transaxle Mount Nuts

Courtesy of FORD MOTOR CO.

26. Install the engine mount and the 3 bolts.

l Tighten to 48 Nm (35 lb-ft).

Fig. 404: Locating Engine Mount And Bolts

Courtesy of FORD MOTOR CO.

27. Install the 2 motor mount nuts.

l Tighten to 90 Nm (66 lb-ft).

Fig. 405: Locating Engine Mount Nuts

Courtesy of FORD MOTOR CO.

28. Install the 2 oil pan-to-bellhousing bolts.

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l Tighten to 48 Nm (35 lb-ft).

Fig. 406: Locating Oil Pan-To-Bell Housing Bolts

Courtesy of FORD MOTOR CO.

29. Install the 2 lower bellhousing-to-oil pan bolts.

l Tighten to 48 Nm (35 lb-ft).

Fig. 407: Locating Lower Bellhousing-To-Oil Pan Bolts

Courtesy of FORD MOTOR CO.

NOTE: The bolts are different lengths, make sure the bolts are in the correct
location.

30. Install the transaxle roll restrictor and the 2 bolts.

1. Install the transaxle roll restrictor.
2. Install the short bolt.
3. Install the long bolt.
l Tighten to 70 Nm (52 lb-ft).

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Fig. 408: Identifying Transaxle Roll Restrictor With Short And Long Bolt
Courtesy of FORD MOTOR CO.

31. Install the transaxle fluid indicator.

Fig. 409: Locating Transaxle Fluid Level Indicator

Courtesy of FORD MOTOR CO.

32. Connect the heater hose to the coolant tube.

Fig. 410: Locating Heater Hose Of Coolant Tube

Courtesy of FORD MOTOR CO.

33. Connect the upper radiator hose and the heater hose to the coolant bypass.

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Fig. 411: Locating Upper Radiator Hose And Heater Hose From Coolant Bypass
Courtesy of FORD MOTOR CO.

34. Connect the coolant degas bottle vent hose to the coolant bypass.

Fig. 412: Locating Coolant Degas Bottle Vent Hose To Coolant Bypass
Courtesy of FORD MOTOR CO.

35. Connect the coolant degas bottle hose and install the retaining clip.

Fig. 413: Locating Coolant Degas Bottle Hose And Retaining Clip
Courtesy of FORD MOTOR CO.

36. Install the power steering pump. For additional information, refer to POWER STEERING .
37. Clean and inspect the exhaust manifold flange. For additional information, refer to Exhaust Manifold

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Cleaning and Inspection in ENGINE SYSTEM - GENERAL INFORMATION .

38. Install the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD .
39. Connect the power steering cooler tube.

Fig. 414: Locating Power Steering Cooler Tube

Courtesy of FORD MOTOR CO.

40. Using 2 new O-ring seals, install the power steering tubes to the steering gear and install the bolt.
l Tighten to 18 Nm (159 lb-in).

Fig. 415: Locating Power Steering Tubes And Bolt

Courtesy of FORD MOTOR CO.

41. Install the power steering tube clip and the bolt.
l Tighten to 10 Nm (89 lb-in).

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Fig. 416: Locating Power Steering Tube Clip Bolt

Courtesy of FORD MOTOR CO.

42. Install the LH and RH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .

NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing
the oil filter.

43. Install a new engine oil filter.

l Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter
adapter.

Fig. 417: Locating Engine Oil Filter

Courtesy of FORD MOTOR CO.

44. Connect the lower radiator hose to the radiator.

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Fig. 418: Locating Lower Radiator Hose To Radiator

Courtesy of FORD MOTOR CO.

45. Install the cooling fan motor and shroud. For additional information, refer to ENGINE COOLING .
46. Using 2 new O-ring seals, connect the A/C tubes to the compressor.

Fig. 419: Locating A/C Tube O-Rings

Courtesy of FORD MOTOR CO.

47. Install the 2 A/C tube-to-compressor nuts.

l Tighten to 15 Nm (133 lb-in).

Fig. 420: Locating A/C Tube-To-Compressor Nuts

Courtesy of FORD MOTOR CO.

48. Position and attach the 2 B+ battery cable wire harness retainers.

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Fig. 421: Locating B+ Battery Cable Wire Harness Retainers From Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.

49. Install the generator. For additional information, refer to CHARGING SYSTEM .
50. Install the accessory drive belt and tensioner. For additional information, refer to ACCESSORY
DRIVE .
51. Install the 2 front wheels and tires. For additional information, refer to WHEELS AND TIRES .
52. Install the engine oil level indicator.

Fig. 422: Locating Engine Oil Level Indicator

Courtesy of FORD MOTOR CO.

53. Install the transmission fluid cooler tubes on the transaxle and slide the latches to the locked position.

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Fig. 423: Installing Transmission Fluid Cooler Tubes On Transaxle

Courtesy of FORD MOTOR CO.

54. Install the secondary latches.

Fig. 424: Locating Transmission Fluid Cooler Tube Secondary Latches

Courtesy of FORD MOTOR CO.

55. Connect the transaxle shift cable to the lever and bracket.

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Fig. 425: Locating Transaxle Shift Cable

Courtesy of FORD MOTOR CO.

56. Connect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors
and attach the wire harness retainer.

Fig. 426: Locating Heated Oxygen Sensor And Catalyst Monitor Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.

57. Connect the starter wire harness electrical connector.

Fig. 427: Locating Starter Wire Harness Electrical Connector

Courtesy of FORD MOTOR CO.

58. Connect the 3 PCM electrical connectors.

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Fig. 428: Locating PCM Electrical Connectors

Courtesy of FORD MOTOR CO.

59. Install the ground wire and nut on the negative battery terminal.
l Tighten to 10 Nm (89 lb-in).

Fig. 429: Locating Ground Wire And Nut On Negative Battery Terminal
Courtesy of FORD MOTOR CO.

60. Attach the engine harness to the coolant outlet bracket harness retainer.

Fig. 430: Locating Engine Harness Of Coolant Outlet Bracket Harness Retainer
Courtesy of FORD MOTOR CO.

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61. Connect and attach the 2 engine harness electrical connectors.

Fig. 431: Locating Engine Harness Electrical Connectors

Courtesy of FORD MOTOR CO.

62. Install the power brake booster vacuum tube into the quick connect fitting.

Fig. 432: Locating Vacuum Tube Of Quick Release Fitting

Courtesy of FORD MOTOR CO.

63. Position and connect the Evaporative Emission (EVAP) tube. For additional information, refer to FUEL
SYSTEM - GENERAL INFORMATION .

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Fig. 433: Locating Evaporative Emission (EVAP) Tube And Position Aside
Courtesy of FORD MOTOR CO.

64. Connect the fuel tube quick connect coupling to the fuel tube near the bulkhead. For additional
information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig. 434: Locating Fuel Tube Quick Connect Coupling From Fuel Tube Near Bulkhead
Courtesy of FORD MOTOR CO.

65. Install the negative battery cable ground and the bolt.
l Tighten to 10 Nm (89 lb-in).

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Fig. 435: Locating Negative Battery Cable Ground Bolt

Courtesy of FORD MOTOR CO.

66. Attach the 3 positive battery cable wire harness retainer.

Fig. 436: Locating Positive Battery Cable Wire Harness Retainers

Courtesy of FORD MOTOR CO.

67. Connect the positive battery cable nut.

l Tighten to 10 Nm (89 lb-in).

Fig. 437: Locating Positive Battery Cable Terminal Nut

Courtesy of FORD MOTOR CO.

68. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
69. Connect the crankcase vent tube to the valve cover.

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Fig. 438: Locating Crankcase Vent Tube

Courtesy of FORD MOTOR CO.

70. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR
DISTRIBUTION & FILTERING .
71. Fill the engine with clean engine oil.
72. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
73. Evacuate and charge the A/C system. For additional information, refer to CLIMATE CONTROL
SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
74. Install the splash shield, pin-type retainer and the 2 bolts.

Fig. 439: Locating Splash Shield, Pin-Type Retainer And Bolts

Courtesy of FORD MOTOR CO.

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