Engine Mechanical: Mechanical: Engine: Assembly: Engine

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Adapter for 205-126	(205-072-02)
Courtesy of FORD MOTOR CO.	Aligner, Clutch Disc	308-006 (T71P-7137-H)
Courtesy of FORD MOTOR CO.	Alignment Plate, Camshaft	303-465 (T94P-6256-CH)
Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane	014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Holding Fixture, Drive Pinion Flange	205-126 (T78P-4851-A)
Courtesy of FORD MOTOR CO.	Installer, Camshaft Front Oil Seal	303-096 (T74P-6150-A)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Main Oil Seal	303-328 (T88P-6701-B1)
Courtesy of FORD MOTOR CO.	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Timing Peg, Crankshaft TDC	303-507

Fig 1: Lower Engine Block Components

Courtesy of FORD MOTOR CO.

Fig 2: Front Engine Block Components

Courtesy of FORD MOTOR CO.

Fig 3: Cylinder Head Components

Courtesy of FORD MOTOR CO.

Fig 4: Intake Manifold Components

Courtesy of FORD MOTOR CO.

All engines 

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.
   • Tighten to 4 Nm (35 lb-in).

   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.

   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.

   Courtesy of FORD MOTOR CO.

4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
   • Tighten the bolts in the sequence shown in 3 stages.
   • Stage 1: Tighten to 5 Nm (44 lb-in).
   • Stage 2: Tighten to 25 Nm (18 lb-ft).
   • Tighten an additional 90 degrees.

   Courtesy of FORD MOTOR CO.

5. Measure each crankshaft block housing main bearing bore diameter.
   • Remove the bolts and the main bearing beam.
   • Discard the main bearing beam bolts.

   Courtesy of FORD MOTOR CO.

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

   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.
   • Tighten the bolts in 2 stages.
   • Stage 1: Tighten to 29 Nm (21 lb-ft).
   • Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
   • Remove the bolts and the connecting rod cap.
   • Discard the connecting rod cap bolts.

   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.

   Courtesy of FORD MOTOR CO.

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

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

    Courtesy of FORD MOTOR CO.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.

    Courtesy of FORD MOTOR CO.

13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.

    Courtesy of FORD MOTOR CO.

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

    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.

    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.
    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Tighten an additional 90 degrees.

    Courtesy of FORD MOTOR CO.

18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
    • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge with Holding Fixture.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • 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.

    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.
19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
    • 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.
    • The position of the upper and lower compression ring gaps are not controlled for installation.

    Courtesy of FORD MOTOR CO.

20. Install the connecting rod caps and bolts.
    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.

    Courtesy of FORD MOTOR CO.

CAUTION: 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).
22. Remove the engine plug bolt.
Fig 5: 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 until the timing drive components and crankshaft pulley are installed.
23. Install the Crankshaft TDC Timing Peg.
Fig 6: Identifying Special Tool (303-507)
Courtesy of FORD MOTOR CO.
NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.
24. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 20 Nm (177 lb-in).
Fig 7: Identifying Tightening Sequence Of Oil Pump Assembly Bolts
Courtesy of FORD MOTOR CO.
25. Using a new oil pump pickup tube gasket, install the pickup tube and bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 8: Locating Oil Pump Pickup Tube Bolts
Courtesy of FORD MOTOR CO.
26. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear seal.
Fig 9: Positioning Crankshaft Rear Oil Seal Using Special Tool (303-328)
Courtesy of FORD MOTOR CO.
27. Tighten the 6 crankshaft rear seal with retainer plate bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
Fig 10: Identifying Tightening Sequence Of Crankshaft Rear Oil Seal Bolts
Courtesy of FORD MOTOR CO.
CAUTION: 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.
28. 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.
29. 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.
Fig 11: Identifying Rear 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 12: Aligning Front Surface Of The Oil Pan
Courtesy of FORD MOTOR CO.
31. Install the remaining 13 oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
Fig 13: Identifying Tightening Sequence Of Oil Pan Bolts
Courtesy of FORD MOTOR CO.
32. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
Fig 14: Identifying Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
33. Apply silicone gasket and sealant to the locations shown.
Fig 15: Identifying Silicone Gasket And Sealant Location
Courtesy of FORD MOTOR CO.
34. Install a new cylinder head gasket.
Fig 16: Identifying 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.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 15 Nm (177 lb-in).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
Fig 17: Identifying Tightening Sequence Of Cylinder Head Bolts
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.
36. Install the valve tappets.
CAUTION: 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:
    • Stage 1: Tighten one turn at a time until tight.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (142 lb-in).
Fig 18: Identifying Camshaft 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.
    • The crankshaft sprocket flange must be facing away from the engine block.
Fig 19: Locating Washers, Oil Pump Chain & Sprockets
Courtesy of FORD MOTOR CO.
39. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 20: Locating Oil Pump Chain, Sprocket & Bolt
Courtesy of FORD MOTOR CO.
40. Install the oil pump chain tensioner shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 21: 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.
    • Tighten to 10 Nm (89 lb-in).
Fig 22: Identifying Tensioner Spring And Shoulder Bolt
Courtesy of FORD MOTOR CO.
CAUTION: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
42. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Fig 23: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
43. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
Fig 24: Locating Camshaft Sprocket Bolts
Courtesy of FORD MOTOR CO.
44. Install the LH timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 25: Identifying Bolts And LH Timing Chain Guide
Courtesy of FORD MOTOR CO.
45. Install the timing chain.
Fig 26: View Of Timing Chain
Courtesy of FORD MOTOR CO.
46. Install the RH timing chain guide.
Fig 27: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
47. Using the edge of a vise, compress the timing chain tensioner plunger.
Fig 28: Locating Timing Chain Tensioner Plunger
Courtesy of FORD MOTOR CO.
48. Using a small pick, push back and hold the ratchet mechanism.
Fig 29: Using A Small Pick To Push Back And Hold Ratchet Mechanism
Courtesy of FORD MOTOR CO.
49. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Fig 30: 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 31: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet Assembly And Plunger
Courtesy of FORD MOTOR CO.
51. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
Fig 32: Locating Timing Chain Tensioner Bolts And Paper Clip
Courtesy of FORD MOTOR CO.
CAUTION: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
52. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts to 72 Nm (53 lb-ft).
Fig 33: Locating Camshaft Bolts
Courtesy of FORD MOTOR CO.
CAUTION: 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.
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.
Fig 34: Locating Silicone Gasket
Courtesy of FORD MOTOR CO.
55. Install the engine front cover. Tighten the 22 bolts in the sequence shown to the following specifications:
    • Tighten the 8-mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
Fig 35: 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.
56. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.
Fig 36: Installing Crankshaft Front Oil Seal Using Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
57. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
Fig 37: Identifying Hole In Crankshaft Pulley At 6 O'Clock Position
Courtesy of FORD MOTOR CO.
CAUTION: 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.
58. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
Fig 38: Identifying Standard 6mm x 18 mm Bolt
Courtesy of FORD MOTOR CO.
CAUTION: 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 Drive Pinion Flange Holding Fixture and Adapter and the bolt should be installed using hand tools only.
CAUTION: Do not reuse the crankshaft pulley bolt.
59. Install a new crankshaft pulley bolt. Using the Drive Pinion Flange Holding Fixture and Adapter to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (one-fourth turn).
Fig 39: Using Special Tools (205-126 And 205-072-02)
Courtesy of FORD MOTOR CO.
60. Remove the 6 mm x 18 mm bolt.
Fig 40: Identifying 6 mm x 18 mm Bolt
Courtesy of FORD MOTOR CO.
61. Remove the Crankshaft TDC Timing Peg.
Fig 41: Identifying Special Tool
Courtesy of FORD MOTOR CO.
62. Remove the Camshaft Alignment Plate.
Fig 42: Identifying Special Camshaft Tool (303-465)
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.
Fig 43: Identifying Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
65. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
Fig 44: Identifying Special Tool (303-507)
Courtesy of FORD MOTOR CO.
CAUTION: 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.
    • If it is not possible to install the bolt, the engine valve timing must be corrected.
Fig 45: Identifying 6 mm x 18 mm Bolt
Courtesy of FORD MOTOR CO.
67. Install the Camshaft Alignment Plate to check the position of the camshafts.
    • If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
Fig 46: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
68. Remove the Camshaft Alignment Plate.
Fig 47: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
69. Install the Crankshaft Position (CKP) sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
Fig 48: Identifying Bolts
Courtesy of FORD MOTOR CO.
70. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
    • Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
Fig 49: Identifying CKP Sensor
Courtesy of FORD MOTOR CO.
71. Remove the 6 mm x 18 mm bolt.
Fig 50: Identifying 6 mm x 18 mm Bolt
Courtesy of FORD MOTOR CO.
72. Remove the Crankshaft TDC Timing Peg.
Fig 51: Identifying Special Tool
Courtesy of FORD MOTOR CO.
73. Install the engine plug bolt.
    • Tighten to 20 Nm (177 lb-in).
Fig 52: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
CAUTION: 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.
Fig 53: Applying Silicone Gasket And Sealant
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.
    • Tighten the 14 bolts in the sequence shown to 10 Nm (89 lb-in).
Fig 54: Identifying Valve Cover Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
CAUTION: 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.
    • Tighten the CHT sensor to 12 Nm (106 lb-in).
    • Tighten the spark plugs to 12 Nm (106 lb-in).
Fig 55: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs
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.
    • Tighten to 10 Nm (89 lb-in).
Fig 56: Identifying Bolts
Courtesy of FORD MOTOR CO.
79. If equipped, install the engine block heater.
    • Tighten to 21 Nm (15 lb-ft).
Fig 57: Locating Block Heater
Courtesy of FORD MOTOR CO.
80. Install the crankcase vent oil separator and the 8 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 58: Identifying Bolts And Crankcase Vent Oil Separator
Courtesy of FORD MOTOR CO.
NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
81. Install the KS and the bolt.
    • Tighten to 20 Nm (177 lb-in).
Fig 59: Locating Knock Sensor Bolt
Courtesy of FORD MOTOR CO.
82. Install the A/C compressor, 2 bolts and the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 60: Identifying Bolts, Stud Bolt And A/C Compressor
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.
    • Tighten to 10 Nm (89 lb-in).
Fig 61: Identifying Bolts, Thermostat Housing And Thermostat
Courtesy of FORD MOTOR CO.
84. Connect the coolant bypass hose.
Fig 62: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
85. Using a new gasket, install the coolant outlet and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 63: Locating Coolant Bypass And Bolts
Courtesy of FORD MOTOR CO.
86. Connect the coolant bypass hose.
Fig 64: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
87. Connect the EGR valve coolant hose.
Fig 65: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
88. Install the radio interference capacitor bracket and bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 66: Identifying Radio Interference Capacitor Bracket Bolt
Courtesy of FORD MOTOR CO.
89. Install the EGR tube.
    • Tighten to 55 Nm (41 lb-ft).
Fig 67: Locating Exhaust Gas Recirculation (EGR) Tube
Courtesy of FORD MOTOR CO.
90. Inspect and install new intake manifold gaskets if necessary.
91. Position the intake manifold and connect the PCV hose.
Fig 68: Identifying PVC Hose Connector Tabs
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.
92. Install the intake manifold and hand-tighten the 2 intake manifold bolts.
Fig 69: Identifying Bolts
Courtesy of FORD MOTOR CO.
93. Install the 5 intake manifold mounting bolts.
    • Tighten all 7 bolts to 18 Nm (159 lb-in).
Fig 70: Identifying Bolts
Courtesy of FORD MOTOR CO.
94. Install the lower intake manifold bolt.
    • Tighten to 18 Nm (159 lb-in).
Fig 71: Locating Lower Intake Manifold Bolt
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new O-ring with clean engine oil.
95. Using a new O-ring seal, install the oil level indicator tube assembly and the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 72: Identifying Bolt And Indicator Tube
Courtesy of FORD MOTOR CO.
96. Connect the EGR valve electrical connector and if equipped, connect the swirl control valve sensor electrical connector.
Fig 73: Identifying EGR Valve Connector And Control Valve Sensor Connector
Courtesy of FORD MOTOR CO.
97. If equipped, connect the swirl control valve solenoid electrical connector.
Fig 74: Locating Swirl Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
98. Connect the Manifold Absolute Pressure (MAP) electrical connector.
Fig 75: Locating Manifold Actual Pressure (MAP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
99. Connect the KS electrical connector and pin-type retainer.
Fig 76: Locating Knock Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
CAUTION: 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.
100. Install new fuel injector O-rings.
     • Separate the fuel injectors from the fuel rail.
     • Remove and discard the fuel injector O-rings.
     • Install new O-rings and lubricate with clean engine oil.
     • Install the fuel injectors onto the fuel rail.
Fig 77: Identifying Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.
101. Install the fuel rail with the fuel injectors and the 2 bolts.
     • Tighten to 25 Nm (18 lb-ft).
Fig 78: Identifying Bolts
Courtesy of FORD MOTOR CO.
102. Connect the 4 fuel injector electrical connectors and attach the wiring harness retainers to valve cover stud bolts and intake manifold.
Fig 79: Identifying Fuel Injector Connectors
Courtesy of FORD MOTOR CO.
103. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
Fig 80: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
Courtesy of FORD MOTOR CO.
104. Connect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
Fig 81: Identifying Coil-On-Plug And Camshaft Position (CMP) 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.
     • Tighten to 25 Nm (18 lb-ft).
Fig 82: Locating Oil Filter Adapter And Bolts
Courtesy of FORD MOTOR CO.
106. Connect the Engine Oil Pressure (EOP) switch electrical connector.
Fig 83: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
107. Connect the heater hose and lower radiator hose to the thermostat housing.
Fig 84: Identifying Radiator Hose And Lower Radiator Hose
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.
108. Position the coolant pump and install the 3 bolts.
     • Tighten to 10 Nm (89 lb-in).
Fig 85: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
109. Install the coolant pump pulley and 3 bolts.
     • Tighten to 20 Nm (177 lb-in).
Fig 86: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
110. Install the accessory drive belt idler pulley.
     • Tighten to 25 Nm (18 lb-ft).
Fig 87: Locating Accessory Drivebelt Idler Pulley And Bolt
Courtesy of FORD MOTOR CO.
111. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
112. Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in 3 stages:
     • Stage 1: Tighten to 50 Nm (37 lb-ft).
     • Stage 2: Tighten to 80 Nm (50 lb-ft).
     • Stage 3: Tighten to 112 Nm (83 lb-ft).
Fig 88: Identifying Flexplate Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.

Engines equipped with a manual transaxle 

113. Lubricate the transaxle input shaft pilot bearing with front axle grease.
Fig 89: Locating Transmission Input Shaft Pilot Bearing
Courtesy of FORD MOTOR CO.
114. Using the Clutch Disc Aligner, position the clutch disc on the flywheel.
Fig 90: Positioning Clutch Disc On Flywheel Using Special Tool (308-006)
Courtesy of FORD MOTOR CO.
NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
115. Position the clutch pressure plate and install the 7 bolts. Tighten the bolts in a star pattern sequence to 27 Nm (20 lb-ft).
Fig 91: Locating Clutch Pressure Plate Bolts
Courtesy of FORD MOTOR CO.