Lower Engine

Fig 1: Exploded View Of Lower Engine

Courtesy of FORD MOTOR CO.

All vehicles 

1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
   Fig 2: Measuring Crankshaft Main Bearing Journal Diameters In Directions

   Courtesy of FORD MOTOR CO.
2. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.
   Fig 3: Locating Original Main Bearing Beam Bolts

   Courtesy of FORD MOTOR CO.
3. Tighten the 10 original main bearing beam bolts in the sequence shown in illustration in 2 stages.
   • Stage 1: Tighten to 19 Nm (168 lb-in).
   • Stage 2: Tighten an additional 60 degrees.
   Fig 4: Identifying Original Main Bearing Beam Bolts Tightening Sequence

   Courtesy of FORD MOTOR CO.
4. Measure each crankshaft block main bearing bore diameter.
   Fig 5: Measuring Crankshaft Block Main Bearing Bore Diameter

   Courtesy of FORD MOTOR CO.
5. Using the chart, select the crankshaft main bearings.
   Fig 6: Crankshaft Main Bearings Selection Chart

   Courtesy of FORD MOTOR CO.
6. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 2 stages.
   • Stage 1: Tighten to 29 Nm (21 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
   Fig 7: Locating Connecting Caps And Bolts

   Courtesy of FORD MOTOR CO.
7. 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.
   Fig 8: Identifying Connecting Rod Large End Bore Measuring Directions

   Courtesy of FORD MOTOR CO.
8. 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 9: Locating Crankshaft Connecting Rod Bearing Journal Diameters In Measuring Directions

   Courtesy of FORD MOTOR CO.
9. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
   Fig 10: Crankshaft Connecting Rod Journal And Correct Connecting Rod Bearings Selection Chart

   Courtesy of FORD MOTOR CO.
NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct orientation for reassembly.
Fig 11: Identifying Main Bearing Beam Bolts In Sequence
Courtesy of FORD MOTOR CO.
10. Remove the 10 bolts in the sequence shown in illustration and the main bearing beam.
    • Discard the main bearing beam bolts.
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.
Fig 12: Lubricating Upper 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 13: Lubricating 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.
NOTE: Lubricate journals on the crankshaft with clean engine oil.
Fig 14: Lubricating Journals On Crankshaft
Courtesy of FORD MOTOR CO.
13. Position the crankshaft in the cylinder block.
14. Lubricate the 10 main bearing beam side fit surfaces and the 5 main bearing beam bearings with clean engine oil.
    Fig 15: Lubricating Main Bearing Beam Side Fit Surfaces And Main Bearing Beam Bearings

    Courtesy of FORD MOTOR CO.
15. 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 16: 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.
Fig 17: Identifying Main Bearing Beam Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
16. Install and tighten the 10 new main bearing beam bolts.
    • Tighten the bolts in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 19 Nm (168 lb-in).
    • Stage 2: Tighten an additional 60 degrees.
17. 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 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
    Fig 18: Measuring Crankshaft End Play

    Courtesy of FORD MOTOR CO.
18. Make sure the dimple in the piston faces the front of the engine.
    Fig 19: Locating Dimple In Piston Faces

    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.
Fig 20: Identifying Piston Ring Compressor And Connecting Rod Installer
Courtesy of FORD MOTOR CO.
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.
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.
Fig 21: Locating Bolts And Connecting Rod Cap
Courtesy of FORD MOTOR CO.
20. Install the connecting rod caps and the new bolts and tighten the bolts in 3 stages.
    • Stage 1: Tighten to 18 Nm (159 lb-in).
    • Stage 2: Wait 2 seconds.
    • Stage 3: Tighten an additional 35 degrees.
21. Install the Crankshaft Top Dead Center (TDC) Timing Pin and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Pin. The engine is now at TDC.
    Fig 22: Installing Crankshaft TDC Pin

    Courtesy of FORD MOTOR CO.
22. Install a new gasket, the oil pump and the 8 bolts in their original position and tighten in sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten to 9 Nm (80 lb-in).
    Fig 23: Identifying Oil Pump And Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
23. Install the windage tray and the 4 bolts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 24: Locating Bolts And Windage Tray

    Courtesy of FORD MOTOR CO.
24. Install the oil pump screen and pickup tube and 3 bolts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 25: Locating Oil Pump Screen And Pickup Tube Bolts

    Courtesy of FORD MOTOR CO.
NOTE: New crankshaft rear seal is supplied with an alignment sleeve which must be removed after installation.
NOTE: Do not remove the alignment sleeve from the crankshaft rear seal prior to installation on the crankshaft.
NOTE: Do not lubricate the new crankshaft rear seal.
Fig 26: Identifying Crankshaft Rear Seal Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
25. Align the crankshaft rear seal and alignment sleeve on the crankshaft and push the crankshaft rear seal off the alignment sleeve onto the crankshaft without stopping until the crankshaft rear seal meets the cylinder block.
    • Install the 6 bolts and tighten in sequence shown in illustration in 2 stages.
      • Stage 1: Tighten bolts 1 through 6 to 4 Nm (35 lb-in).
      • Stage 2: Tighten bolts 1 through 6 to 9 Nm (80 lb-in).
26. Remove the alignment sleeve taking care not to touch the sealing lip.
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.
27. Clean and inspect all oil pan mating surfaces.
28. Install 2 M8x20 studs for oil pan alignment.
    Fig 27: Locating Oil Pan Alignment And M8X20 Studs

    Courtesy of FORD MOTOR CO.
NOTE: The oil pan must be installed within 5 minutes of applying the sealant.
NOTE: If the oil pan is not secured within 5 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 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Fig 28: Applying Bead Of Sealant To Oil Pan
Courtesy of FORD MOTOR CO.
29. Apply a 3.5 mm (0.137 in) bead of sealant to the oil pan.
30. Install the oil pan using the 2 studs for alignment.
    Fig 29: Locating Oil Pan Studs

    Courtesy of FORD MOTOR CO.
31. Install 11 bolts finger tight and remove the 2 alignment studs and install the remaining 2 bolts finger tight.
    Fig 30: Locating Oil Pan Bolts

    Courtesy of FORD MOTOR CO.
32. Tighten the oil pan bolts in the following sequence in 2 stages.
    • Stage 1: Tighten bolts 1 through 13 to 10 Nm (89 lb-in).
    • Stage 2: Tighten bolts 1 through 13 to 20 Nm (177 lb-in).
    Fig 31: Identifying Oil Pan 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
33. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
    1. 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.
34. Install the cylinder head alignment dowels.
    • Dowels must be fully seated in the cylinder block.
    Fig 32: Identifying Cylinder Head Alignment Dowels

    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.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Fig 33: Identifying Cylinder Head Gasket And Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
35. Install the cylinder head gasket, cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in 4 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 15 Nm (133 lb-in).
    • Stage 3: Tighten to 35 Nm (26 lb-ft).
    • Stage 4: Turn 75 degrees.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
Fig 34: Identifying Camshafts And Valve Tappets
Courtesy of FORD MOTOR CO.
36. Install the valve tappets.
37. If removed, install the camshaft trigger wheels and the 2 bolts.
    • Tighten to 21 Nm (15 lb-ft).
    Fig 35: Identifying Bolts And Camshaft Trigger Wheels

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the camshafts with clean engine oil.
Fig 36: Identifying Camshafts
Courtesy of FORD MOTOR CO.
38. Install the camshafts as shown in illustration.
39. Install the Variable Camshaft Timing (VCT) bridge O-ring seal.
    Fig 37: Identifying VCT Bridge O-Ring Seal

    Courtesy of FORD MOTOR CO.
NOTE: The VCT bridge must be installed within 5 minutes of applying the gasket maker to the cylinder head.
Fig 38: Identifying Gasket Maker Applying Area To Cylinder Head
Courtesy of FORD MOTOR CO.
40. Apply a 1.5 mm (0.059 in) bead of gasket maker to the cylinder head as shown in illustration.
NOTE: Make sure that the camshafts and camshaft bearing caps are installed in their original locations or damage to the engine may occur.
NOTE: Apply clean engine oil to the bearing surfaces of the camshaft bearing caps and the VCT bridge.
Fig 39: Locating Camshaft Bearing Caps, VCT Bridge And Bolts
Courtesy of FORD MOTOR CO.
41. Install the camshaft bearing caps, VCT bridge and the bolts finger tight.
42. Tighten the bolts in the sequence shown in illustration in 6 stages.
    • Stage 1: Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head.
    • Stage 2: Tighten bolts 1 through 16 to 7 Nm (62 lb-in).
    • Stage 3: Tighten bolts 17 through 20 to 10 Nm (89 lb-in).
    • Stage 4: Tighten bolts 1 through 16 an additional 45 degrees.
    • Stage 5: Tighten bolts 17 and 19 an additional 70 degrees.
    • Stage 6: Tighten bolts 18 and 20 an additional 53 degrees.
    Fig 40: Identifying Camshaft Bearing Caps And Variable Camshaft Timing (VCT) Bridge Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
43. If the cylinder head, camshafts or valve tappets were replaced, check the valve clearance. For additional information, REFER to Valve Clearance Check .
44. Using the Camshaft Seal Installer, install the 2 camshaft oil seals.
    Fig 41: Installing Camshaft Oil Seals

    Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon to align the camshafts.
Fig 42: Installing Camshaft Alignment Plate Into End Of Camshafts
Courtesy of FORD MOTOR CO.
45. Install the Camshaft Alignment Plate into the end of the camshafts.
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
NOTE: The timing marks of the camshaft phaser and sprocket must be at the 12 o'clock position.
Fig 43: Locating Camshaft Phaser And Sprockets Bolts
Courtesy of FORD MOTOR CO.
46. Install the 2 camshaft phaser and sprocket, bolts and the VCT Alignment Tool.
    • Tighten the 2 bolts to 25 Nm (18 lb-ft).
47. Remove the VCT Alignment Tool.
    Fig 44: Removing VCT Alignment Tool

    Courtesy of FORD MOTOR CO.
48. Remove the Camshaft Alignment Plate.
    Fig 45: Removing Camshaft Alignment Plate

    Courtesy of FORD MOTOR CO.
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Fig 46: Locating Camshaft Phaser And Sprocket Bolts
Courtesy of FORD MOTOR CO.
49. Tighten to 2 camshaft phaser and sprocket bolts an additional 75 degrees.
NOTE: The special tool can only be installed if the valve timing is correct.
Fig 47: Installing Camshaft Alignment Plate Into End Of Camshafts
Courtesy of FORD MOTOR CO.
50. Install the Camshaft Alignment Plate into the end of the camshafts.
NOTE: The special tool can only be installed if the valve timing is correct.
Fig 48: Installing VCT Alignment Tool
Courtesy of FORD MOTOR CO.
51. Install the VCT Alignment Tool.
    • If the special tools cannot be installed, repeat the adjustment according to the preceding steps.
52. Remove the VCT Alignment Tool.
    Fig 49: Removing VCT Alignment Tool

    Courtesy of FORD MOTOR CO.
53. Remove the Camshaft Alignment Plate.
    Fig 50: Removing Camshaft Alignment Plate

    Courtesy of FORD MOTOR CO.
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Fig 51: Locating Camshaft Phaser And Sprocket Plugs
Courtesy of FORD MOTOR CO.
54. Install the 2 camshaft phaser and sprocket plugs.
    • Tighten to 16 Nm (142 lb-in).
55. Install the VCT Alignment Tool.
    Fig 52: Installing VCT Alignment Tool

    Courtesy of FORD MOTOR CO.
56. Install the 4 spark plugs.
    • Tighten to 15 Nm (133 lb-in).
    Fig 53: Identifying Spark Plugs

    Courtesy of FORD MOTOR CO.
57. Using a new gasket, install the coolant pump, 6 bolts and tighten in sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    Fig 54: Identifying Coolant Pump Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
58. Install the timing belt tensioner and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    • Rotate the timing belt tensioner clockwise and align the 2 holes on the tensioner and install a small screwdriver or holding pin.
    Fig 55: Identifying Bolt And Timing Belt Tensioner

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the oil seal with clean engine oil.
Fig 56: Installing Crankshaft Front Oil Seal
Courtesy of FORD MOTOR CO.
59. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Front Crankshaft Seal Replacer, install the crankshaft front oil seal.
60. Install the crankshaft sprocket gear.
    Fig 57: Identifying Crankshaft Sprocket Gear

    Courtesy of FORD MOTOR CO.
61. Install the timing belt cover backplate and the 4 bolts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 58: Locating Bolts And Timing Belt Cover Backplate

    Courtesy of FORD MOTOR CO.
62. Install the timing belt in the sequence shown in illustration.
    Fig 59: Identifying Timing Belt In Sequence

    Courtesy of FORD MOTOR CO.
WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.
Fig 60: Locating Timing Belt Tensioner Holding Tool
Courtesy of FORD MOTOR CO.
63. Remove the timing belt tensioner holding tool.
64. Install the lower timing belt cover and the 3 bolts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 61: Locating Bolts And Lower Timing Belt Cover

    Courtesy of FORD MOTOR CO.
65. Install the crankshaft pulley and the new bolt.
    • Tighten to 100 Nm (74 lb-ft).
    • The final torque of the crankshaft will be completed in following steps.
    Fig 62: Identifying Crankshaft Pulley And Bolt

    Courtesy of FORD MOTOR CO.
66. Remove the Crankshaft TDC Timing Pin.
    Fig 63: Removing Crankshaft TDC Pin

    Courtesy of FORD MOTOR CO.
67. Remove the VCT Alignment Tool.
    Fig 64: Removing VCT Alignment Tool

    Courtesy of FORD MOTOR CO.
68. Tighten the crankshaft bolt in the following 3 stages.
    1. Stage 1: Using the Strap wrench, tighten an additional 90 degrees.
    2. Stage 2: Wait for 10 seconds.
    3. Stage 3: Using the Strap wrench, tighten an additional 15 degrees.
    Fig 65: Locating Crankshaft Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Only rotate the crankshaft clockwise direction.
Fig 66: Rotating Crankshaft Clockwise
Courtesy of FORD MOTOR CO.
69. Rotate the crankshaft about 1 3/4 turns.
70. Install the Crankshaft TDC Timing Pin.
    Fig 67: Installing Crankshaft TDC Pin

    Courtesy of FORD MOTOR CO.
NOTE: Only rotate the crankshaft clockwise direction.
Fig 68: Rotating Crankshaft Clockwise
Courtesy of FORD MOTOR CO.
71. Rotate the crankshaft until it stops against the Crankshaft TDC Timing Pin.
NOTE: The special tool can only be installed if the valve timing is correct.
Fig 69: Installing VCT Alignment Tool
Courtesy of FORD MOTOR CO.
72. Install the VCT Alignment Tool.
    • If the special tool cannot be installed, repeat the adjustment according to the preceding steps.
73. Remove the VCT Alignment Tool.
    Fig 70: Removing VCT Alignment Tool

    Courtesy of FORD MOTOR CO.
74. Remove the Crankshaft TDC Timing Pin.
    Fig 71: Removing Crankshaft TDC Pin

    Courtesy of FORD MOTOR CO.
75. Install the engine plug bolt.
    • Tighten to 20 Nm (177 lb-in).
    Fig 72: Locating Engine Plug Bolt

    Courtesy of FORD MOTOR CO.
76. Install the engine mount bracket and the 3 bolts finger tight.
    1. Tighten the 2 bolts to 55 Nm (41 lb-ft).
    2. Tighten the bolt to 55 Nm (41 lb-ft).
    Fig 73: Identifying Engine Mount Bracket And Bolts

    Courtesy of FORD MOTOR CO.
77. Install the timing belt cover and the 9 bolts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 74: Locating Bolts And Timing Belt Cover

    Courtesy of FORD MOTOR CO.
78. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 20 Nm (177 lb-in).
    Fig 75: Locating Bolts And Coolant Pump Pulley

    Courtesy of FORD MOTOR CO.
79. Install the 1 engine mount stud finger tight.
    Fig 76: Locating Engine Mount Stud

    Courtesy of FORD MOTOR CO.
NOTE: The 2 engine mount studs must be torqued or damage to the powertrain may occur.
Fig 77: Locating Engine Mount Studs
Courtesy of FORD MOTOR CO.
80. Torque the 2 engine mount studs before installing the engine mount nuts.
    • Tighten to 8 Nm (71 lb-in).
81. Using a new gasket, install the valve cover and tighten the retainers in sequence shown in illustration.
    • Tighten to 9 Nm (80 lb-in).
    Fig 78: Identifying Valve Cover And Retainers Tightening Sequence

    Courtesy of FORD MOTOR CO.
82. Install the Heated Oxygen Sensor (HO2S) electrical connector bracket and the nut.
    • Tighten to 8 Nm (71 lb-in).
    Fig 79: Identifying Heated Oxygen Sensor (HO2S) Electrical Connector Bracket And Nut

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seals with clean engine oil.
Fig 80: Identifying Variable Camshaft Timing (VCT) Oil Control Solenoids And Bolts
Courtesy of FORD MOTOR CO.
83. Install the VCT oil control solenoids and the 2 bolts.
    • Tighten to 8 Nm (71 lb-in).
84. Install the Crankshaft Position (CKP) sensor and the bolt.
    • Tighten to 8 Nm (71 lb-in).
    Fig 81: Identifying Crankshaft Position (CKP) Sensor And Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Apply thread sealant to the Engine Oil Pressure (EOP) switch threads.
Fig 82: Identifying Engine Oil Pressure (EOP) Switch
Courtesy of FORD MOTOR CO.
85. Install the EOP switch.
    • Tighten to 18 Nm (159 lb-in).
86. Install the crankcase vent oil separator and the bolts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 83: Locating Bolts And Crankcase Vent Oil Separator

    Courtesy of FORD MOTOR CO.
87. Install the RH Knock Sensor (KS) at the 2 o'clock position and the LH KS at the 11 o'clock position and install the bolts.
    • Tighten to 20 Nm (177 lb-in).
    Fig 84: Identifying KS Bolts

    Courtesy of FORD MOTOR CO.
88. Install the thermostat and seal in the engine block.
    Fig 85: Identifying Thermostat And Engine Block

    Courtesy of FORD MOTOR CO.
89. Install the gasket, thermostat housing and the 4 bolts finger tight. Tighten the bolts in sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    Fig 86: Identifying Thermostat Housing And Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
Fig 87: Identifying Bolt And Oil Cooler
Courtesy of FORD MOTOR CO.
90. Install the new oil cooler and the bolt.
    • Tighten to 56 Nm (41 lb-ft).
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 88: Locating Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.
91. Inspect and install new intake manifold gaskets if necessary.
92. Install the intake manifold and the 7 bolts.
    • Connect the PCV hose to the intake manifold.
    • Tighten to 18 Nm (159 lb-in).
    Fig 89: Locating Bolts And Intake Manifold

    Courtesy of FORD MOTOR CO.
93. Attach the KS electrical connector to the intake manifold.
    Fig 90: Locating Knock Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
NOTE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
Fig 91: Identifying Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.
94. Install the new O-ring seals onto the fuel injectors and lubricate them with clean engine oil.
95. Install the 4 fuel injectors and the 4 fuel injector clips into the fuel rail.
    Fig 92: Identifying Fuel Injector Clips And Fuel Injectors

    Courtesy of FORD MOTOR CO.
96. Install the fuel rail and fuel injectors as an assembly and install the 2 bolts.
    • Tighten to 11 Nm (97 lb-in).
    Fig 93: Identifying Fuel Rail Assembly And Bolts

    Courtesy of FORD MOTOR CO.
97. If equipped, position the block heater and finger-tighten the nut, making sure the block heater electrical connector points to the 8 o'clock position.
    • Tighten the nut to 3 Nm (27 lb-in).
    Fig 94: Locating Engine Block Heater

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil.
Fig 95: Identifying Oil Level Indicator Tube And Screw
Courtesy of FORD MOTOR CO.
98. Install the oil level indicator and tube and the screw.
    • Tighten to 4 Nm (35 lb-in).
99. Install the LH engine lift eye and the 2 bolts.
    • Tighten to 19 Nm (168 lb-in).
    Fig 96: Identifying Bolts And Engine Lift Eye

    Courtesy of FORD MOTOR CO.
100. Install the ignition coil and coolant outlet assembly and the 4 bolts.
     • Tighten to 19 Nm (168 lb-in).
     Fig 97: Identifying Coolant Outlet And Ignition Coil Assembly Bolts

     Courtesy of FORD MOTOR CO.
101. Install the coolant outlet bracket, nut and the bolt.
     • Tighten to 6 Nm (53 lb-in).
     Fig 98: Locating Coolant Outlet Bracket Nut And Bolt

     Courtesy of FORD MOTOR CO.
102. Connect the coolant return hose to the cylinder head.
     • Attach the coolant tube to the fuel rail retainers.
     Fig 99: Identifying Coolant Tube To Fuel Rail Retainers

     Courtesy of FORD MOTOR CO.
103. Connect the coolant hose to the coolant outlet.
     Fig 100: Identifying Coolant Hose To Coolant Outlet

     Courtesy of FORD MOTOR CO.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
Fig 101: Identifying Spark Plug Wires
Courtesy of FORD MOTOR CO.
104. Install the 4 spark plug wires.
105. Install the Evaporative Emission (EVAP) canister purge valve and the bolt.
     • Tighten to 9 Nm (80 lb-in).
     Fig 102: Identifying EVAP Canister Purge Valve Bolt

     Courtesy of FORD MOTOR CO.
106. Attach the EVAP tube and coolant tube to the coolant outlet bracket retainer.
     Fig 103: Identifying EVAP Tube And Coolant Tube To Coolant Outlet Bracket Retainer

     Courtesy of FORD MOTOR CO.
107. Connect the brake booster vacuum tube to the intake manifold.
     Fig 104: Identifying Brake Booster Vacuum Tube To Intake Manifold

     Courtesy of FORD MOTOR CO.
108. Connect the EVAP canister purge valve tube to the intake manifold.
     Fig 105: Identifying Evaporative Emission (EVAP) Canister Purge Valve Tube To Intake Manifold

     Courtesy of FORD MOTOR CO.
109. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.

     Vehicles with automatic transaxle 

110. Align the flexplate and crankshaft using the dowel pin location hole and install the new bolts finger tight.
     Fig 106: Locating Flexplate Bolts

     Courtesy of FORD MOTOR CO.
111. Install the Flywheel Holding Tool.
     Fig 107: Installing Flywheel Holding Tool

     Courtesy of FORD MOTOR CO.
112. Tighten the bolts in the sequence shown in illustration in 2 stages:
     • Stage 1: Tighten to 30 Nm (22 lb-ft).
     • Stage 2: Tighten an additional 80 degrees.
     Fig 108: Identifying Flexplate Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.

     Vehicles with manual transaxle 

113. Align the flywheel and crankshaft using the dowel pin location hole and install the new bolts finger tight.
     Fig 109: Locating Flywheel Bolts

     Courtesy of FORD MOTOR CO.
114. Install the Flywheel Holding Tool.
     Fig 110: Installing Flywheel Holding Tool

     Courtesy of FORD MOTOR CO.
115. Tighten the bolts in the sequence shown in illustration in 2 stages:
     • Stage 1: Tighten to 30 Nm (22 lb-ft).
     • Stage 2: Tighten an additional 80 degrees.
     Fig 111: Identifying Flywheel Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
NOTE: Be sure the clutch is installed correctly in the pressure plate. The side of the clutch marked gearbox side faces the pressure plate fingers. Failure to install the clutch plate will damage the clutch assembly during installation on the flywheel.
NOTE: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent or damage may occur.
Fig 112: Identifying Clutch Disc On Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
116. Position the clutch disc on the clutch pressure plate with the side of the clutch marked gearbox side facing the pressure plate fingers. Using a suitable clutch aligner, centralize the clutch disc to the clutch pressure plate.
NOTE: Use a clutch disc aligner (such as OTC® Clutch Alignment Tool Set 4528 or equivalent).
Fig 113: Locating Clutch Pressure Plate-To-Flywheel Bolts
Courtesy of FORD MOTOR CO.
117. Using a clutch disc aligner, position the clutch disc and clutch pressure plate on the flywheel. Install the 6 new clutch pressure plate-to-flywheel bolts.
     • Tighten the bolts evenly two turns at a time in the pattern shown in illustration.
     • Tighten to 29 Nm (21 lb-ft).