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Section 3190 (Engine - 2.7L ECOBOOST (238KW/324PS)): Assembly: Engine

WARNING: This page is about a different car, the 2017 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) / General Equipment 

GFD16095Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W) Handle
GFD16773Courtesy of FORD MOTOR COMPANY
 303-1246 Engine Spreader Bar

TKIT-2006UF-FLM

TKIT-2006UF-ROW
GFD16096Courtesy of FORD MOTOR COMPANY
 303-1247 VCT Spark Plug Tube Seal Remover and Installer

TKIT-2006UF-FLM

TKIT-2006UF-ROW
GFD16444Courtesy of FORD MOTOR COMPANY
 303-1248 Camshaft holding tools

TKIT-2006UF-FLM

TKIT-2006UF-ROW
GFD16647Courtesy of FORD MOTOR COMPANY
 303-1250 Seal Installer, Rear Main

TKIT-2006UFFLM
GFD16445Courtesy of FORD MOTOR COMPANY
 303-1531 Installer, Front Crank Seal and Damper
GFD16446Courtesy of FORD MOTOR COMPANY
 303-1633 Remover, Roller Rocker Follower

TKIT-2014D-FL_ROW

TKIT-2014D-ROW3
GFD16774Courtesy of FORD MOTOR COMPANY
 303-1634 Lift Eyes (2)

TKIT-2014D-FL_ROW

TKIT-2014D-ROW3
GFD16447Courtesy of FORD MOTOR COMPANY
 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal

TKIT-1988-F

TKIT-1988-FLM
Strap Wrench
Floor Crane
Mounting Stand
Hose Clamp Remover/Installer
Flat-Bladed Screwdriver
Piston Ring Compressor
Vise
Vise Jaw Protectors

Materials 

Name Specification
Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) XO-5W30-QSP (U.S.) WSS-M2C946-A
Motorcraft® High Performance Engine RTV Silicone TA-357 WSE-M4G323-A6
Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) VC-3DIL-B (U.S.) WSS-M97B44-D2
Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.) VC-3-B (U.S.) WSS-M97B44-D
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: If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.
NOTE: Refer to the exploded view under the Engine Component View in the DESCRIPTION AND OPERATION .

  1. 1.

    Read and record the four character code on the cylinder block face, they are arranged as follows: *##*##*. The first letter after the first asterisk is the code for main No. 1 and the next letter for main No, 2. The first letter after the second asterisk is the code for main No. 3 and the last letter for main No. 4.
GFD16867Courtesy of FORD MOTOR COMPANY

  1. 2.

    Read and record the four character code on the crankshaft face, they are arranged as follows: *##*##*. The first letter after the first asterisk is the code for main No. 1 and the next letter for main No, 2. The first letter after the second asterisk is the code for main No. 3 and the last letter for main No. 4.
GFD16868Courtesy of FORD MOTOR COMPANY

  1. 3.

    Using the data recorded earlier and the Bearing Select Fit Chart, determine the required bearing grade for the main bearings.

    1. 1.

      Look at the bearing select fit chart and for each main, match the block and crankshaft code with its corresponding column or row by reading across the crankshaft row and down the block column to select the proper grade bearings for each main.

    1. 2.

      For example, if the block code is *BL*KH* and the crankshaft code is *SU*TQ*, main No. 1 should be assembled with grade 1 bearings, as determined by the intersection of the

      B  block column and the

      S  crankshaft row. Mains No. 2, 3 and 4 should all be grade 2.

GFD16869Courtesy of FORD MOTOR COMPANY

  1. 4.

    Install the piston cooling jets and bolts into the cylinder block.

    Torque

    : 89 lb.in (10 Nm)

GFD16830Courtesy of FORD MOTOR COMPANY

  1. 5.

    Install the crankshaft main bearings.
    • Install the crankshaft upper main bearings and thrust bearing into the cylinder block.
    • Install the crankshaft lower main bearings into the bearing caps.
    • Make sure all oil passages are aligned.
    • Lubricate all main bearings with clean engine oil.

      Material

      : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16870Courtesy of FORD MOTOR COMPANY

  1. 6.

    NOTE: Lubricate the crankshaft bearing journals with clean engine oil.

    Install the crankshaft into the cylinder block.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16871Courtesy of FORD MOTOR COMPANY

  1. 7.

    Install the No. 1, 2 and 3 main bearing caps and bolts on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the cap bolts.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16872Courtesy of FORD MOTOR COMPANY

  1. 8.

    NOTE: Lubricate the lower thrust washer with clean engine oil.

    Install the lower thrust washer and the No. 4 main bearing cap and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap bolts.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16873Courtesy of FORD MOTOR COMPANY

  1. 9.

    Push the crankshaft forward to seat the crankshaft thrust washer.
GFD16874Courtesy of FORD MOTOR COMPANY

  1. 10.

    Tighten the main bearing cap bolts.

    Torque:

    Stage 1: 30 lb.ft (40 Nm)

    Stage 2: Loosen: 360°

    Stage 3: 26 lb.ft (35 Nm)

    Stage 4: 180°

Fig 1: Main Bearing Tightening Sequence
GFD16875Courtesy of FORD MOTOR COMPANY

  1. 11.

    • Check the piston-to-cylinder block and piston ring clearances. Refer to: Specifications .
    • Assemble the pistons and position the piston ring gaps. Refer to: Piston .

  1. 12.

    Lubricate with clean engine oil and install the connecting rod bearings.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16876Courtesy of FORD MOTOR COMPANY

  1. 13.

    1. 1.

      For assembly purposes the bump on the connecting rod will face the same way as the bump on the connecting rod cap.
GFD16858Courtesy of FORD MOTOR COMPANY

  1. 14.

    1. 1.

      For assembly purposes the bowl on the dome of the piston should be facing toward the intake of the engine.

    1. 2.

      On the RH bank the bump on the connecting rod should face the front of the engine.

    1. 3.

      On the LH bank the bump on the connecting rod should face the rear of the engine.
GFD16859Courtesy of FORD MOTOR COMPANY

  1. 15.

    NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
    NOTE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.
    NOTE: Lubricate the piston with clean engine oil.
    • Position the piston assembly and piston ring installer into the cylinder.

      Use the General Equipment: Piston Ring Compressor

      Material

      : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

      NOTE: A commercially available piston rod installer must be used to prevent damage to the crankshaft journal.
    • Install a piston rod installer over the crankshaft journal and into the bolt holes of the connecting rod.
    • Push the piston into the cylinder bore and guide the connecting rod onto the crankshaft journal.
GFD16877Courtesy of FORD MOTOR COMPANY

  1. 16.

    NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

    1. 1.

      Install the connecting rod cap and bearing.

      Torque:

      Stage 1: 24 lb.ft (32 Nm)

      Stage 2: Loosen: 180°

      Stage 3: 24 lb.ft (32 Nm)

      Stage 4: 90°

    1. 2.

      Repeat the steps for each of the remaining pistons.
GFD16878Courtesy of FORD MOTOR COMPANY

  1. 17.

    NOTE: If the engine block skirt stiffener is not installed, aligned and the bolts tightened to minimum specification within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply a 3.5 mm (0.14 in) bead of Motorcraft® High Performance Engine RTV Silicone to the cylinder block.

    Material

    : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD16879Courtesy of FORD MOTOR COMPANY

  1. 18.

    1. 1.

      Position the oil seal.

    1. 2.

      Install the engine block skirt stiffener.
GFD16880Courtesy of FORD MOTOR COMPANY

  1. 19.

    1. 1.

      Install the bolts finger tight.

    1. 2.

      Tighten the 2 bolts.

      Torque:

      Stage 1: 35 lb.in (4 Nm)

      Stage 2: Loosen: 360°

GFD16881Courtesy of FORD MOTOR COMPANY

  1. 20.

    1. 1.

      Using a straight edge, align the rear face of the engine block skirt stiffener to the rear face of the engine block, flush or up to 0.250 mm (0.01 in) underflush.

    1. 2.

      Using a straight edge, align the machined bosses on the left side of the engine block skirt stiffener to the machined bosses on the left side of the engine block flush or within 0.280 mm (0.011) of flush.
GFD16882Courtesy of FORD MOTOR COMPANY

  1. 21.

    NOTE: If the engine block skirt stiffener bolts minimal torque is not completed within 10 minutes of sealant application, or if final torque is not met within 60 minutes of sealant application the parts must be removed and the sealant must be removed and the sealing area cleaned.

    Tighten the engine block skirt stiffener bolts.

    Torque:

    Stage 1: 35 lb.in (4 Nm)

    Stage 2: 18 lb.ft (24 Nm)

GFD16883Courtesy of FORD MOTOR COMPANY

  1. 22.

    NOTE: Do not reuse the ECT sensor, install a new sensor.

    Install a new ECT sensor.

    Torque

    : 20 lb.ft (27 Nm)

GFD16884Courtesy of FORD MOTOR COMPANY

  1. 23.

    1. 1.

      Install the KS assembly and the bolts.

      Torque

      : 97 lb.in (11 Nm)

    1. 2.

      Connect the ECT sensor electrical connector.
GFD16885Courtesy of FORD MOTOR COMPANY

  1. 24.

    Inspect the coolant outlet connector pipe gasket and replace if damaged.
GFD16886Courtesy of FORD MOTOR COMPANY

  1. 25.

    1. 1.

      Install the coolant outlet connector pipe, the bolts and the stud bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Attach the wiring harness retainer to the stud bolt.
GFD16887Courtesy of FORD MOTOR COMPANY

  1. 26.

    Install the timing chain sprocket.
GFD16765Courtesy of FORD MOTOR COMPANY

  1. 27.

    Install the crankshaft pulley bolt and rotate the crankshaft clockwise until the keyway is at the 9 o'clock position.
GFD16888Courtesy of FORD MOTOR COMPANY

  1. 28.

    Install a new cylinder head gasket.
GFD16681Courtesy of FORD MOTOR COMPANY

  1. 29.

    • Install the cylinder head.
    • Install new cylinder head bolts.

      Torque:

      Stage 1: 177 lb.in (20 Nm)

      Stage 2: Loosen: 2 turn(s)

      Stage 3: 37 lb.ft (50 Nm)

      Stage 4: 180°

GFD16682Courtesy of FORD MOTOR COMPANY

  1. 30.

    Inspect the O-ring and replace if damaged.
GFD16686Courtesy of FORD MOTOR COMPANY

  1. 31.

    1. 1.

      Install the cylinder head to coolant outlet connector hose assembly and the bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Connect the coolant hose and the clamp.

      Use the General Equipment: Hose Clamp Remover/Installer

GFD16889Courtesy of FORD MOTOR COMPANY

  1. 32.

    NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.
    NOTE: If the original hydraulic lash adjusters are to be reinstalled, they must be installed in their original locations.

    1. 1.

      Lubricate the hydraulic lash adjusters with clean engine oil.

      Material

      : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

    1. 2.

      Install the hydraulic lash adjusters.
GFD16550Courtesy of FORD MOTOR COMPANY

  1. 33.

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

    Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16551Courtesy of FORD MOTOR COMPANY

  1. 34.

    NOTE: Do not tighten at this time.

    Install the camshaft bearing caps and the bolts.

GFD16552Courtesy of FORD MOTOR COMPANY

  1. 35.

    NOTE: Do not tighten at this time.

    Install the front camshaft bearing mega cap and the 4 bolts.

GFD16553Courtesy of FORD MOTOR COMPANY

  1. 36.

    Tighten the bolts.

    Torque

    : 133 lb.in (15 Nm)

GFD16554Courtesy of FORD MOTOR COMPANY

  1. 37.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For installation of the LH side the circle marks are used.

    1. 1.

      Install the VCT units. The circle  timing marks on the VCT units will be at the 10 o'clock (intake) and 12:30 (exhaust) positions as shown in the illustration.

      Install Special Service Tool: 303-1248 Camshaft holding tools.

    1. 2.

      Install the new VCT unit bolts.

      Torque:

      Stage 1: 30 lb.ft (40 Nm)

      Stage 2: Loosen: 360°

      Stage 3: 37 lb.ft (50 Nm)

      Stage 4: 90°

    1. 3.

      Remove Special Service Tool: 303-1248 Camshaft holding tools.
GFD16555Courtesy of FORD MOTOR COMPANY

  1. 38.

    Install a new cylinder head gasket.
GFD16718Courtesy of FORD MOTOR COMPANY

  1. 39.

    • Install the cylinder head.
    • Install new cylinder head bolts.

      Torque:

      Stage 1: 177 lb.in (20 Nm)

      Stage 2: Loosen: 2 turn(s)

      Stage 3: 37 lb.ft (50 Nm)

      Stage 4: 180°

GFD16719Courtesy of FORD MOTOR COMPANY

  1. 40.

    Inspect the O-ring and replace if damaged.
GFD16686Courtesy of FORD MOTOR COMPANY

  1. 41.

    1. 1.

      Install the cylinder head to coolant outlet connector hose assembly and the bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Connect the coolant hose and the clamp.

      Use the General Equipment: Hose Clamp Remover/Installer

GFD16890Courtesy of FORD MOTOR COMPANY

  1. 42.

    NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.
    NOTE: If the original hydraulic lash adjusters are to be reinstalled, they must be installed in their original locations.

    1. 1.

      Lubricate the hydraulic lash adjusters with clean engine oil.

      Material

      : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

    1. 2.

      Install the hydraulic lash adjusters.
GFD16627Courtesy of FORD MOTOR COMPANY

  1. 43.

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

    Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16628Courtesy of FORD MOTOR COMPANY

  1. 44.

    NOTE: Do not tighten at this time.

    Install the camshaft bearing caps and the bolts.

GFD16629Courtesy of FORD MOTOR COMPANY

  1. 45.

    NOTE: Do not tighten at this time.

    Install the front camshaft bearing mega cap and the 4 bolts.

GFD16630Courtesy of FORD MOTOR COMPANY

  1. 46.

    Tighten the bolts.

    Torque

    : 133 lb.in (15 Nm)

GFD16631Courtesy of FORD MOTOR COMPANY

  1. 47.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For installation of the RH side the triangle marks are used.

    1. 1.

      Install the VCT units. The triangle  timing marks on the VCT units will be at the 2 o'clock (intake) and 11 o'clock (exhaust) positions as shown in the illustration.

      Install Special Service Tool: 303-1248 Camshaft holding tools.

    1. 2.

      Install the new VCT unit bolts.

      Torque:

      Stage 1: 30 lb.ft (40 Nm)

      Stage 2: Loosen: 360°

      Stage 3: 37 lb.ft (50 Nm)

      Stage 4: 90°

    1. 3.

      Remove Special Service Tool: 303-1248 Camshaft holding tools.
GFD16632Courtesy of FORD MOTOR COMPANY

  1. 48.

    Install the oil pump and the bolts.

    Torque:

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 45°

GFD16815Courtesy of FORD MOTOR COMPANY

  1. 49.

    Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the keyway is at the 11 o'clock position.
GFD16891Courtesy of FORD MOTOR COMPANY

  1. 50.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the LH side the circle marks are used.

    1. 1.

      Install the LH timing chain with the single colored links aligned with the circle  timing marks on the VCT units.

    1. 2.

      Install the double colored links so they straddle the timing mark on the crankshaft sprocket.
GFD16556Courtesy of FORD MOTOR COMPANY

  1. 51.

    Install the LH timing chain guide and bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16543Courtesy of FORD MOTOR COMPANY

  1. 52.

    Install the LH timing chain tensioner arm.
GFD16542Courtesy of FORD MOTOR COMPANY

  1. 53.

    Slide the tensioner cylinder out of the LH timing chain tensioner housing.
GFD16557Courtesy of FORD MOTOR COMPANY

  1. 54.

    NOTE: Use vise jaw protectors or cover the jaws of the vise with clean shop towels to prevent damage to the surface of the tensioner ratchet mechanism.

    Mount the flat machined surfaces on the end of the tensioner cylinder into a vise.

    1. 1.

      Using a flat-bladed screwdriver apply light downward pressure on the end of the tensioner ratchet mechanism.

      Use the General Equipment: Vise

      Use the General Equipment: Vise Jaw Protectors

      Use the General Equipment: Flat-Bladed Screwdriver

    1. 2.

      Rotate the screwdriver clockwise approximately one turn.

    1. 3.

      An audible click will be heard when the tensioner ratchet mechanism locks into place.
GFD16558Courtesy of FORD MOTOR COMPANY

  1. 55.

    1. 1.

      Slide the tensioner cylinder into the LH timing chain tensioner housing to the fully retracted position.

    1. 2.

      Install a retaining pin into the hole in the housing to lock the cylinder in the retracted position.
GFD16559Courtesy of FORD MOTOR COMPANY

  1. 56.

    1. 1.

      Position the LH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.

    1. 2.

      Install the bolts.

      Torque

      : 89 lb.in (10 Nm)

    1. 3.

      Remove the pin.
GFD16560Courtesy of FORD MOTOR COMPANY

  1. 57.

    Install the oil pump drive chain.
GFD16540Courtesy of FORD MOTOR COMPANY

  1. 58.

    Install the oil pump drive chain guide and bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16539Courtesy of FORD MOTOR COMPANY

  1. 59.

    1. 1.

      Install the oil pump drive chain tensioner and bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Remove the pin.
GFD16561Courtesy of FORD MOTOR COMPANY

  1. 60.

    1. 1.

      Rotate the crankshaft clockwise one revolution (360 degrees).

    1. 2.

      Position the crankshaft sprocket keyway at the 11 o'clock position.
GFD16562Courtesy of FORD MOTOR COMPANY

  1. 61.

    Remove the crankshaft pulley bolt.
GFD16535Courtesy of FORD MOTOR COMPANY

  1. 62.

    Install the timing chain sprocket.
GFD16534Courtesy of FORD MOTOR COMPANY

  1. 63.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the RH side the triangle marks are used.

    1. 1.

      Install the RH timing chain with the single colored links aligned with the triangle  timing marks on the VCT units.

    1. 2.

      Install the double colored links so they straddle the timing mark on the crankshaft sprocket.
GFD16563Courtesy of FORD MOTOR COMPANY

  1. 64.

    Install the RH timing chain guide and bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16531Courtesy of FORD MOTOR COMPANY

  1. 65.

    Install the RH timing chain tensioner arm.
GFD16530Courtesy of FORD MOTOR COMPANY

  1. 66.

    Slide the tensioner cylinder out of the RH timing chain tensioner housing.
GFD16564Courtesy of FORD MOTOR COMPANY

  1. 67.

    NOTE: Use vise jaw protectors or cover the jaws of the vise with clean shop towels to prevent damage to the surface of the tensioner ratchet mechanism.

    Mount the flat machined surfaces on the end of the tensioner cylinder into a vise.

    1. 1.

      Using a flat-bladed screwdriver apply light downward pressure on the end of the tensioner ratchet mechanism.

      Use the General Equipment: Vise

      Use the General Equipment: Vise Jaw Protectors

      Use the General Equipment: Flat-Bladed Screwdriver

    1. 2.

      Rotate the screwdriver clockwise approximately one turn.

    1. 3.

      An audible click will be heard when the tensioner ratchet mechanism locks into place.
GFD16558Courtesy of FORD MOTOR COMPANY

  1. 68.

    1. 1.

      Slide the tensioner cylinder into the RH timing chain tensioner housing to the fully retracted position.

    1. 2.

      Install a retaining pin into the hole in the housing to lock the cylinder in the retracted position.
GFD16565Courtesy of FORD MOTOR COMPANY

  1. 69.

    1. 1.

      Position the RH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.

    1. 2.

      Install the bolts.

      Torque

      : 89 lb.in (10 Nm)

    1. 3.

      Remove the pin.
GFD16566Courtesy of FORD MOTOR COMPANY

  1. 70.

    Install new engine front cover gaskets.
GFD16567Courtesy of FORD MOTOR COMPANY

  1. 71.

    Lubricate and install a new oil gallery seal.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16568Courtesy of FORD MOTOR COMPANY

  1. 72.

      NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
      NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.
    • Apply a 3.5 mm (0.14 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine block sealing surfaces including the inner bolt bosses.

      Material

      : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    • Apply a 5.5 mm (0.22 in) bead of Motorcraft® High Performance Engine RTV Silicone to the cylinder block skirt-to-cylinder block joint and the cylinder head-to-cylinder block joint areas as indicated.

      Material

      : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD16569Courtesy of FORD MOTOR COMPANY

  1. 73.

    Install the engine front cover and the fasteners.

    Torque:

    Stage 1: Tighten bolts 1 thru 11 to: 18 lb.ft (24 Nm)

    Stage 2: Tighten bolts 12 thru 13 to: 35 lb.ft (48 Nm)

    Stage 3: Tighten bolts 14 thru 21 to: 18 lb.ft (24 Nm)

GFD16570Courtesy of FORD MOTOR COMPANY

  1. 74.

    Lubricate the engine front cover bore with clean engine oil.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16576Courtesy of FORD MOTOR COMPANY

  1. 75.

    Using the special tools, install the new crankshaft front oil seal.

    Use Special Service Tool: 303-335 (T88T-6701-A) installer, Front Cover Oil Seal, 303-1531 installer, Front Crank Seal and Damper.

GFD16577Courtesy of FORD MOTOR COMPANY

  1. 76.

    Lubricate the crankshaft front seal inner lip with clean engine oil.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16578Courtesy of FORD MOTOR COMPANY

  1. 77.

    Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16579Courtesy of FORD MOTOR COMPANY

  1. 78.

    Using the special tools, install the crankshaft pulley.

    Use Special Service Tool: 303-335 (T88T-6701-A) installer, Front Cover Oil Seal, 303-1531 installer, Front Crank Seal and Damper.

GFD16580Courtesy of FORD MOTOR COMPANY

  1. 79.

    Using the Strap Wrench, install a new crankshaft pulley bolt.

    Use the General Equipment: Strap Wrench

    Torque:

    Stage 1: 166 lb.ft (225 Nm)

    Stage 2: Loosen: 360°

    Stage 3: 26 lb.ft (35 Nm)

    Stage 4: 270°

GFD16581Courtesy of FORD MOTOR COMPANY

  1. 80.

    Rotate the crankshaft pulley bolt clockwise to position the camshaft lobe upward for the camshaft roller follower to be installed.
GFD16640Courtesy of FORD MOTOR COMPANY

  1. 81.

    1. 1.

      Install Special Service Tool: 303-1633 Remover, Roller Rocker Follower.

    1. 2.

      Turn the knob on the special tool clockwise to depress the valve and spring.
GFD16641Courtesy of FORD MOTOR COMPANY

  1. 82.

    1. 1.

      Lubricate the camshaft roller follower with clean engine oil.

      Material

      : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

    1. 2.

      Install the camshaft roller follower.

    1. 3.

      Turn the knob on the special tool counterclockwise to raise the valve and spring.

      Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower.

    • Repeat steps for the remaining camshaft roller followers.
GFD16642Courtesy of FORD MOTOR COMPANY

  1. 83.

    NOTE: Installation of new seals is only required if damaged seals were removed.

    Using the special tools, install new spark plug tube seals.

    Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

GFD16585Courtesy of FORD MOTOR COMPANY

  1. 84.

    Install a new gasket.
GFD16586Courtesy of FORD MOTOR COMPANY

  1. 85.

    Apply clean engine oil to the surface.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16892Courtesy of FORD MOTOR COMPANY

  1. 86.

    NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.

    Material

    : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD16588Courtesy of FORD MOTOR COMPANY

  1. 87.

    Install the valve cover and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16589Courtesy of FORD MOTOR COMPANY

  1. 88.

    NOTE: Installation of new seals is only required if damaged seals were removed.

    Using the special tools, install new spark plug tube seals.

    Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

GFD16590Courtesy of FORD MOTOR COMPANY

  1. 89.

    Install a new gasket.
GFD16591Courtesy of FORD MOTOR COMPANY

  1. 90.

    Apply clean engine oil to the surface.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16893Courtesy of FORD MOTOR COMPANY

  1. 91.

    NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.

    Material

    : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD16593Courtesy of FORD MOTOR COMPANY

  1. 92.

    Install the valve cover and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16594Courtesy of FORD MOTOR COMPANY

  1. 93.

    Install a new oil pump seal.
GFD16604Courtesy of FORD MOTOR COMPANY

  1. 94.

    NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The oil pan must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    1. 1.

      Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the engine.

      Material

      : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    1. 2.

      Apply a 6.5 mm (0.26 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder block joints.

      Material

      : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    1. 3.

      Inspect the crankcase ventilation passages to make sure they are not blocked by any sealer applied.
GFD16605Courtesy of FORD MOTOR COMPANY

  1. 95.

    Install the oil pan and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16894Courtesy of FORD MOTOR COMPANY

  1. 96.

    If removed install and then tighten the TC mounting studs.

    Torque

    : 102 lb.in (11.5 Nm)

GFD16712Courtesy of FORD MOTOR COMPANY

  1. 97.

    Install the new TC gasket.
GFD16721Courtesy of FORD MOTOR COMPANY

  1. 98.

    Install a new TC coolant supply tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

    Material

    : Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) / VC-3DIL-B (U.S.) (WSS-M97B44-D2)

GFD16688Courtesy of FORD MOTOR COMPANY

  1. 99.

    Install the new TC oil supply tube O-ring seals and the new oil filter. Lubricate the new TC oil supply tube O-ring seals with clean engine oil.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16722Courtesy of FORD MOTOR COMPANY

  1. 100.

    Install the TC oil supply tube and the bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD16723Courtesy of FORD MOTOR COMPANY

  1. 101.

    NOTE: Be careful not to damage the new filter when installing the oil supply tube into the engine block.

    Position the TC assembly onto the studs. Install the coolant supply and oil supply tubes into the engine block while installing the TC.

GFD16724Courtesy of FORD MOTOR COMPANY

  1. 102.

    Install the nuts and bolt.

    Torque:

    1: 44 lb.ft (60 Nm)

    2: 44 lb.ft (60 Nm)

    3: 27 lb.ft (37 Nm)

    Re-tighten 1: 44 lb.ft (60 Nm)

    Re-tighten 2: 44 lb.ft (60 Nm)

    Re-tighten 3: 27 lb.ft (37 Nm)

Fig 2: Turbocharger Tightening Sequence
GFD16725Courtesy of FORD MOTOR COMPANY

  1. 103.

    Install the TC coolant supply tube bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD16726Courtesy of FORD MOTOR COMPANY

  1. 104.

    Install the TC oil supply tube bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD16727Courtesy of FORD MOTOR COMPANY

  1. 105.

    Install the new TC oil return tube-to-engine block gasket.
GFD16694Courtesy of FORD MOTOR COMPANY

  1. 106.

    Install a new TC oil return tube O-ring seal and then lubricate with clean engine oil.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16695Courtesy of FORD MOTOR COMPANY

  1. 107.

    NOTE: AWD shown in illustration FWD is similar.

    Install the TC oil return tube and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16708Courtesy of FORD MOTOR COMPANY

  1. 108.

    Install a new TC coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

    Material

    : Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) / VC-3DIL-B (U.S.) (WSS-M97B44-D2)

GFD16728Courtesy of FORD MOTOR COMPANY

  1. 109.

    Install the TC coolant return tube to the TC and install the bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD16705Courtesy of FORD MOTOR COMPANY

  1. 110.

    • Install new TC mounting studs.

      Torque

      : 102 lb.in (11.5 Nm)

    • Install a new TC gasket.
GFD16687Courtesy of FORD MOTOR COMPANY

  1. 111.

    Install a new TC coolant supply tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

    Material

    : Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) / VC-3DIL-B (U.S.) (WSS-M97B44-D2)

GFD16688Courtesy of FORD MOTOR COMPANY

  1. 112.

    Install the new TC oil supply tube O-ring seals and the new oil filter. Lubricate the new TC oil supply tube O-ring seals with clean engine oil.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16689Courtesy of FORD MOTOR COMPANY

  1. 113.

    Install the TC oil supply tube and the bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD16690Courtesy of FORD MOTOR COMPANY

  1. 114.

    NOTE: Be careful not to damage the new filter when installing the oil supply tube into the engine block.

    Position the TC assembly onto the studs. Install the coolant supply and oil supply tubes into the engine block while installing the TC.

GFD16691Courtesy of FORD MOTOR COMPANY

  1. 115.

    Install the nuts and bolt.

    Torque:

    1: 44 lb.ft (60 Nm)

    2: 44 lb.ft (60 Nm)

    3: 27 lb.ft (37 Nm)

    Re-tighten 1: 44 lb.ft (60 Nm)

    Re-tighten 2: 44 lb.ft (60 Nm)

    Re-tighten 3: 27 lb.ft (37 Nm)

GFD16692Courtesy of FORD MOTOR COMPANY

  1. 116.

    Install the TC coolant supply and oil supply tube bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16693Courtesy of FORD MOTOR COMPANY

  1. 117.

    Connect the TC coolant return hose.

    Use the General Equipment: Hose Clamp Remover/Installer

GFD16671Courtesy of FORD MOTOR COMPANY

  1. 118.

    Install the new TC oil return tube-to-engine block gasket.
GFD16694Courtesy of FORD MOTOR COMPANY

  1. 119.

    Install a new TC oil return tube O-ring seal and then lubricate with clean engine oil.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16695Courtesy of FORD MOTOR COMPANY

  1. 120.

    Install the TC oil return tube, then install and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16668Courtesy of FORD MOTOR COMPANY

  1. 121.

    • Lubricate the inside and the outside diameter of the grommet with clean engine coolant.

      Material

      : Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.) / VC-3-B (U.S.) (WSS-M97B44-D)

    • Install the grommet so it is flush with the rear of the coolant pump housing.
GFD16574Courtesy of FORD MOTOR COMPANY

  1. 122.

    NOTE: Verify the front cover dowel pins are aligned to the coolant pump and that the coolant pump is fully seated prior to installing the fasteners.
    • Using a new gasket, install the coolant pump and the fasteners.

      Torque:

      Fasteners 1-7:

      Stage 1: 89 lb.in (10 Nm)

      Stage 2: 45°

    • Torque:

      Fastener 8: 18 lb.ft (24 Nm)

Fig 3: Coolant Pump Tightening Sequence
GFD16575Courtesy of FORD MOTOR COMPANY

  1. 123.

    Inspect the gaskets and replace if damaged.
GFD16571Courtesy of FORD MOTOR COMPANY

  1. 124.

    NOTE: If the brake vacuum pump is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Failure to follow this procedure can cause future oil leakage.

    Apply 8 mm (0.14 in) beads of Motorcraft® High Performance Engine RTV Silicone as shown in illustration.

GFD16572Courtesy of FORD MOTOR COMPANY

  1. 125.

    Install the brake vacuum pump and the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16814Courtesy of FORD MOTOR COMPANY

  1. 126.

    Install a new fuel rail-to-fuel rail high-pressure fuel tube and finger tighten the flare nuts.
    • Final tighten the flare nuts.

      Torque:

      Stage 1: 62 lb.in (7 Nm)

      Stage 2: 89 lb.in (10 Nm)

      Stage 3: 25°

GFD16683Courtesy of FORD MOTOR COMPANY

  1. 127.

    Inspect the high-pressure fuel pump drive unit gasket and replace if damaged.
GFD16633Courtesy of FORD MOTOR COMPANY

  1. 128.

    Apply 8 mm dots of sealant to the camshaft bearing cap and cylinder head seam as shown in illustration.

    Material

    : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD16634Courtesy of FORD MOTOR COMPANY

  1. 129.

    Install the high-pressure fuel pump drive unit and stud bolts.

    Torque:

    Stage 1: 177 lb.in (20 Nm)

    Stage 2: 45°

GFD16635Courtesy of FORD MOTOR COMPANY

  1. 130.

    NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.
    NOTE: The drive lobe for the high-pressure fuel pump must be at BDC (bottom dead center) for the high-pressure fuel pump installation.

    Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC.

GFD16636Courtesy of FORD MOTOR COMPANY

  1. 131.

    NOTE: Align the notch on the high-pressure fuel pump tappet and with the groove in the high-pressure fuel pump drive unit bore.

    Apply clean engine oil to the high-pressure fuel pump drive unit bore, the drive lobe and the roller tappet. Install the high-pressure fuel pump tappet.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16637Courtesy of FORD MOTOR COMPANY

  1. 132.

    NOTE: Apply clean engine oil to the high-pressure fuel pump O-ring seals.

    Install a new high-pressure fuel pump O-ring seal and lubricate with clean engine oil.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16638Courtesy of FORD MOTOR COMPANY

  1. 133.

    Install the high-pressure fuel pump, then install and finger tighten the high-pressure fuel pump nuts. Alternately tighten each of the high-pressure fuel pump nuts one complete revolution until seated. Then tighten the fuel high-pressure fuel pump nuts in the following 2 stages.

    Torque:

    Stage 1: 177 lb.in (20 Nm)

    Stage 2: 45°

GFD16616Courtesy of FORD MOTOR COMPANY

  1. 134.

    NOTE: Make sure that a new high-pressure fuel pump-to-fuel rail high-pressure fuel tube is installed.

    Install the high-pressure fuel pump-to-fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

    Torque:

    Stage 1: 62 lb.in (7 Nm)

    Stage 2: 89 lb.in (10 Nm)

    Stage 3: 25°

GFD16639Courtesy of FORD MOTOR COMPANY

  1. 135.

    Install the gaskets.
GFD16752Courtesy of FORD MOTOR COMPANY

  1. 136.

    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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Install the intake manifold and tighten the bolts.

    Torque

    : 89 lb.in (10 Nm)

GFD16895Courtesy of FORD MOTOR COMPANY

  1. 137.

    Inspect and replace any ignition coil-on-plugs that have rubber boots with cracks, rips or tears.
GFD16896Courtesy of FORD MOTOR COMPANY

  1. 138.

    1. 1.

      Install the ignition coil-on-plugs.

    1. 2.

      Install and tighten the ignition coil-on-plug stud bolts.

      Torque

      : 53 lb.in (6 Nm)

GFD16502Courtesy of FORD MOTOR COMPANY

  1. 139.

    Install the oil level indicator.
GFD16493Courtesy of FORD MOTOR COMPANY

  1. 140.

    Install the EVAP purge valve and connect the quick release coupling. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).
GFD16897Courtesy of FORD MOTOR COMPANY

  1. 141.

    1. 1.

      Install the vacuum tube assembly onto the engine and connect the vacuum hose and clamp to the TC.

    1. 2.

      Install the vacuum control solenoid bolts.

      Torque

      : 62 lb.in (7 Nm)

    1. 3.

      Connect the vacuum tube quick release coupling. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).

    1. 4.

      Attach the vacuum hose retainers.
GFD16812Courtesy of FORD MOTOR COMPANY

  1. 142.

    Connect the vacuum hose and clamp to the TC.
    • Attach the vacuum hose retainers.
GFD16811Courtesy of FORD MOTOR COMPANY

  1. 143.

    Install the engine wiring harness onto the engine.
    • Connect the engine wiring harness electrical connectors and attach the retainers.
GFD16810Courtesy of FORD MOTOR COMPANY

  1. 144.

    • Connect the engine wiring harness electrical connectors and attach the wiring harness retainers.
    • Slide the insulator down over the CHT electrical connector.
GFD16898Courtesy of FORD MOTOR COMPANY

  1. 145.

    1. 1.

      Install the vacuum harness pressure sensor bolt.

      Torque

      : 62 lb.in (7 Nm)

    1. 2.

      Connect the MAP sensor electrical connector.

    1. 3.

      Attach the wiring harness and vacuum harness retainers.
GFD16488Courtesy of FORD MOTOR COMPANY

  1. 146.

    Connect the engine wiring harness electrical connectors and attach the retainers.
GFD16487Courtesy of FORD MOTOR COMPANY

  1. 147.

    1. 1.

      Install the EVAP purge valve onto the intake manifold mounting tab.

    1. 2.

      Disconnect the EVAP tube quick release coupling. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).

    1. 3.

      Connect the EVAP purge valve electrical connector.
GFD16899Courtesy of FORD MOTOR COMPANY

  1. 148.

    Install the EVAP tube and connect the quick release coupling. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).
GFD16807Courtesy of FORD MOTOR COMPANY

  1. 149.

    • Install the PCV tube and connect the quick release coupling. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).
    • Connect the crankcase pressure sensor electrical connector.
    • Attach the PCV tube retainer.
GFD16485Courtesy of FORD MOTOR COMPANY

  1. 150.

    • Install the PCV tube and connect the quick release couplings. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).

    1. 1.

      Connect the throttle body electrical connector and attach the wiring harness retainer.
GFD16806Courtesy of FORD MOTOR COMPANY

  1. 151.

    • Install the ground wire and stud bolt.

      Torque

      : 89 lb.in (10 Nm)

    • Connect the high pressure fuel pump electrical connector.
    • Attach the wiring harness retainers.
GFD16805Courtesy of FORD MOTOR COMPANY

  1. 152.

    Install the ground wire and stud bolt.

    Torque

    : 89 lb.in (10 Nm)

GFD16804Courtesy of FORD MOTOR COMPANY

  1. 153.

    • Install the bracket, the nut and bolt.

      Torque

      : 53 lb.in (6 Nm)

    • Connect the KS electrical connector.
    • Attach the wiring harness retainer.
GFD16803Courtesy of FORD MOTOR COMPANY

  1. 154.

    Attach the wiring harness retainers.
GFD16496Courtesy of FORD MOTOR COMPANY

  1. 155.

    • Install the oil pressure control solenoid and the retainer.

      Torque

      : 97 lb.in (11 Nm)

    • Disconnect the oil pressure control solenoid electrical connector.
GFD16802Courtesy of FORD MOTOR COMPANY

  1. 156.

    • Install the generator stud.

      Torque

      : 71 lb.in (8 Nm)

    • Install the generator and the bolt.

      Torque

      : 35 lb.ft (47 Nm)

    • Install the coolant pump pulley and the bolts.

      Torque

      : 89 lb.in (10 Nm)

    • Install the idler pulley and bolt.

      Torque

      : 35 lb.ft (48 Nm)

    • Install the accessory drive belt tensioner and the bolts.

      Torque

      : 18 lb.ft (25 Nm)

GFD16900Courtesy of FORD MOTOR COMPANY

  1. 157.

    Using a floor crane, remove the engine from the mounting stand.

    Install Special Service Tool: 303-1634 Lift Eyes (2), 303-1246 Engine Spreader Bar.

    Use the General Equipment: Floor Crane

    Use the General Equipment: Mounting Stand

GFD16800Courtesy of FORD MOTOR COMPANY

  1. 158.

    Lubricate the crankshaft rear seal lips with clean engine oil.

    Material

    : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W30-QSP (U.S.) (WSS-M2C946-A)

GFD16653Courtesy of FORD MOTOR COMPANY

  1. 159.

    NOTE: The crankshaft rear seal and retainer plate must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    Apply a 3.5 mm (0.14 in) bead of Motorcraft® High Performance Engine RTV Silicone to the crankshaft rear seal and retainer plate.

    Material

    : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

GFD16654Courtesy of FORD MOTOR COMPANY

  1. 160.

    • Position the special tool onto the end of the crankshaft.

      Use Special Service Tool: 303-1250 Seal Installer, Rear Main.

    • Slide the new crankshaft rear seal and retainer plate onto the tool and into the installed position.
GFD16655Courtesy of FORD MOTOR COMPANY

  1. 161.

    Install the crankshaft rear seal retainer plate bolts.

    Remove Special Service Tool: 303-1250 Seal Installer, Rear Main.

    Torque

    : 89 lb.in (10 Nm)

GFD16656Courtesy of FORD MOTOR COMPANY

  1. 162.

    1. 1.

      Install the CKP sensor and the bolt.

      Torque

      : 89 lb.in (10 Nm)

    1. 2.

      Connect the CKP sensor electrical connector.
GFD16901Courtesy of FORD MOTOR COMPANY

  1. 163.

    Install the crankshaft sensor ring.
GFD16648Courtesy of FORD MOTOR COMPANY

  1. 164.

    1. 1.

      Position the flexplate on the crankshaft.

    1. 2.

      Install the bolts then rundown the bolts one turn at a time in sequence shown in illustration until the flexplate is snug against the rear face of the crankshaft.

    1. 3.

      Final tighten the bolts in sequence shown in illustration.

      Torque

      : 59 lb.ft (80 Nm)

GFD16746Courtesy of FORD MOTOR COMPANY
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