Engine - 2.3L ECOBOOST (231KW/314PS): Assembly: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C)Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W)Handle
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-096 (T74P-6150-A)Installer, Camshaft Front Oil SealTKIT-2009TC-F
Courtesy of FORD MOTOR COMPANY	303-103 (T74P-6375-A)Holding Tool, FlywheelT74P-77000-ATKIT-2009TC-F
Courtesy of FORD MOTOR COMPANY	303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1521Alignment Tool, Crankshaft Position SensorTKIT-2010C-FLM
Courtesy of FORD MOTOR COMPANY	303-1565Alignment Tool, CamshaftTKIT-2010C-FLM
Courtesy of FORD MOTOR COMPANY	303-1567Sizer, Teflon SealTKIT-2010C-FLM
Courtesy of FORD MOTOR COMPANY	303-328 (T88P-6701-B1)Replacer, Rear SealTKIT-1988-FLMTKIT-1988-FTKIT-1988-LM
Courtesy of FORD MOTOR COMPANY	303-507Timing Peg, Crankshaft TDCTKIT-2001N-FLMTKIT-2001N-ROW
Courtesy of FORD MOTOR COMPANY	310-205Fuel Injector Brush
Courtesy of FORD MOTOR COMPANY	310-207Installer, Fuel Injector Seal AssemblyTKIT-2009A-FLM
Feeler Gauge
Mounting Stand
Clutch Alignment Tool
Hose Clamp Remover/Installer
Round-Ended Steel Rule
Piston Ring Compressor

Materials 

6-Speed Manual Transmission - MT82/10-Speed Automatic Transmission - 10R80 

1. Install the engine piston oil cooler valves and the bolts.

   Torque: 89 lb.in (10 Nm)

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2. • Measure the length or distance in two directions.
   • Record the smallest measurement for each crankshaft main bearing journal.

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3. Using the original bolts, mount the main bearing beam flush and install the bolts finger tight.

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4. Tighten the bolts in sequence shown below.

   Torque: Stage 1: 44 lb.in (5 Nm) | Stage 2: 18 lb.ft (25 Nm) | Stage 3: 90 deg.

   Fig 1: Main Bearing Beam Flush Tightening Sequence

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5. Measure each crankshaft block main bearing bore diameter.

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6. NOTE: The bearing color corresponds to the number marked on the bearing.

   Using the chart, select the correct grade main bearings.

   1. Crankshaft journal diameter
   2. Cylinder block bore diameter
   3. Upper Bearing Green: 1 / Lower Bearing Green: 1
   4. Upper Bearing Blue: 2 / Lower Bearing Green: 1
   5. Upper Bearing Blue: 2 / Lower Bearing Blue: 2
   6. Upper Bearing Red: 3 / Lower Bearing Blue: 2
   7. Upper Bearing Red: 3 / Lower Bearing Red: 3
   8. Upper Bearing Brown: 4 / Lower Bearing Red: 3
   9. Upper Bearing Brown: 4 / Lower Bearing Brown: 4
   10. Upper Bearing Yellow: 5 / Lower Bearing Brown: 4
   11. Upper Bearing Yellow: 5 / Lower Bearing Yellow: 5
   12. Upper Bearing Black: 6 / Lower Bearing Yellow: 5
   13. Upper Bearing Black: 6 / Lower Bearing Black: 6
   14. Upper Bearing Blue/Green: 7 / Lower Bearing Black: 6
   15. Upper Bearing Blue/Green: 7 / Lower Bearing Blue/Green: 7

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7. Using the original bolts, install the connecting rod caps.

   Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: Loosen: 1turn(s) | Stage 3: 21 lb.ft (29 Nm) | Stage 4: 90 deg.

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8. • Measure the length or distance in two directions.
   • Record the smallest measurement for each connecting rod.

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9. • Remove the bolts and the connecting rod caps.
   • Discard the bolts.

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10. • Measure the length or distance in two directions.
    • Record the smallest measurement for each connecting rod journal.

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11. NOTE: The bearing color corresponds to the number marked on the bearing.

    Using the chart, select the correct grade connecting rod bearings.

    1. Crankshaft journal diameter
    2. Connecting rod diameter
    3. Upper Bearing Green: 1 / Lower Bearing Green: 1
    4. Upper Bearing Green: 1/ Lower Bearing Blue: 2
    5. Upper Bearing Blue: 2 / Lower Bearing Blue: 2
    6. Upper Bearing Blue: 2/ Lower Bearing Red: 3
    7. Upper Bearing Red: 3 / Lower Bearing Red: 3

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12. • Remove the bolts in sequence shown below.
    • Remove the main bearing beam.
    • Discard the bolts.
    Fig 2: Main Bearing Beam Bolts Removal Sequence

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13. 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.

    Lubricate with clean engine oil and install the crankshaft main bearings.

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

    Lubricate with clean engine oil and install the main bearing beam bearings.

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15. Lubricate with clean engine oil and install the crankshaft.

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16. Lubricate with clean engine oil.

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17. Install the main bearing beam flush.

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18. NOTE: Lubricate the new 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.

    Install the bolts and tighten in sequence shown below.

    Torque: Stage 1: 44 lb.in (5 Nm) | Stage 2: 18 lb.ft (25 Nm) | Stage 3: 90 deg.

    Fig 3: Main Bearing Beam Bolts Tightening Sequence

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19. 1. Position the crankshaft to the rear of the cylinder block.
    2. Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    3. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    4. Acceptable crankshaft end play is 0.220-0.450 mm (0.0087-0.0177 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.

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

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

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21. NOTE: Align the piston rings on the piston.
    1. Upper oil control segment ring gap location.
    2. Oil control spacer gap location.
    3. Lower oil control segment ring gap location.

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22. • Lubricate the pistons with clean engine oil.
    • 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: Make sure the piston arrow on top is facing toward the front of the engine.

      Using a piston ring compressor, install the pistons. Use the General Equipment: Piston Ring Compressor

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23. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

    Install the connecting rod caps, bolts and tighten in 3 stages.

    Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: Loosen: 1turn(s) | Stage 3: 21 lb.ft (29 Nm) | Stage 4: 90 deg.

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24. • Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    • Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC.

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25. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
    NOTE: The original adjustment shims must be installed in their original positions.
    NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.

    Install the adjustment shims in their original positions on the seat faces of the balancer unit. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.

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26. Install the bolts and tighten in 2 stages.

    Torque: Stage 1: 18 lb.ft (25 Nm) | Stage 2: 31 lb.ft (42 Nm)

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27. • Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    • Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.

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28. 1. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    2. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC.
    3. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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29. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown below. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown below into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown below.
    NOTE: Position the Dial Indicator Gauge with Holding Fixture as shown below. Measure the gear backlash.
    1. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    2. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
    3. Backlash specifications are 0.040 to 0.140 mm (0.00157 to 0.0055 in).
    4. If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. Refer to: Balance Shaft Backlash .

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30. Install the special tool and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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31. Install the new oil pump gasket.

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32. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
33. Install the oil pump and the bolts and tighten in the sequence shown below in 2 stages.

    Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 177 lb.in (20 Nm)

    Fig 4: Oil Pump Bolts Tightening Sequence

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34. Install the oil pump sprocket and bolt.

    Torque: 18 lb.ft (25 Nm)

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35. Install the crankshaft sprocket.

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36. 1. Install the timing chain, tensioner and the shoulder bolts.

       Torque: 89 lb.in (10 Nm)

    2. Push the tensioner spring down and position the spring under the shoulder bolt.

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37. • Using the special tool, position the crankshaft rear oil seal onto the crankshaft. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.
    • Install the bolts and tighten in sequence shown below.

      Torque: 89 lb.in (10 Nm)

    Fig 5: Crankshaft Rear Oil Seal Retainer Tightening Sequence

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38. Install the new oil pump screen and pickup tube gasket.

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39. Install the oil pickup and screen and the bolts.

    Torque: 89 lb.in (10 Nm)

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

    Apply a 3 mm bead of silicone sealant.

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

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41. Install the oil pan and the bolts finger tight.

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42. Using a straight edge, align the front surface of the oil pan flush with the front surface of the engine block. Use the General Equipment: Round-Ended Steel Rule

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43. Tighten the bolts in sequence shown below.

    Torque: 18 lb.ft (25 Nm)

    Fig 6: Oil Pan Bolts Tightening Sequence

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44. Install the cylinder block bushings.

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45. Install a new cylinder head gasket.

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

    Install the cylinder head, bolts and tighten in sequence shown below in 5 stages.

    Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 133 lb.in (15 Nm) | Stage 3: 41 lb.ft (55 Nm) | Stage 4: 90 deg. | Stage 5: 90 deg.

    Fig 7: Cylinder Head Bolts Tightening Sequence

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47. NOTE: Lubricate the valve tappets with clean engine oil.

    Lubricate with clean engine oil and install the valve tappets.

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48. NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance, follow the next 12 steps exactly or serious damage to the engine may occur. If the original parts are being installed it is not necessary to check the valve clearance so proceed to  step 61.

    Install the crankshaft bolt and place a paint mark on the crankshaft bolt at the 12 o'clock position.

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49. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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50. NOTE: Rotating the crankshaft will position all of the pistons below the deck of the cylinder block and allow the camshafts to be installed and the valve clearance checked without the possibility of damage to the valves or pistons.

    Using the crankshaft bolt and washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position.

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51. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.
    NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil.
    • Lubricate the camshafts and caps with clean engine oil and install the camshafts, caps and bolts.
    • Tighten 2 turns at a time in the sequence shown below in 2 stages.

      Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 142 lb.in (16 Nm)

    Fig 8: Camshafts Caps Bolts Tightening Sequence

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52. Lubricate the camshaft journals with clean engine oil and install the front camshaft bearing cap and bolts.

    Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 142 lb.in (16 Nm)

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53. 1. Using the flats of the camshaft, rotate the camshaft to place the cam lobe at base circle, with the lobe pointed away from the tappet.
    2. Use a feeler gauge to measure the clearance of each valve and record its location. Use the General Equipment: Feeler Gauge
    3. Repeat to measure all of the lobe/tappet clearances.

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54. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
    NOTE: Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance.
    NOTE: The nominal clearance is:
    • intake: 0.25 mm (0.0095 in).
    • exhaust: 0.36 mm (0.0142 in).
    NOTE: The acceptable clearances after being fully installed are:
    • intake: 0.19-0.31 mm (0.007-0.012 in).
    • exhaust: 0.30-0.42 mm (0.012-0.017 in).
    Select the closest tappet size to the ideal tappet thickness available and mark the installation location.

55. Remove the bolts and the front camshaft bearing cap.

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

    Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps and remove the bolts, caps and camshafts.

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57. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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58. NOTE: Rotating the crankshaft will position the engine at TDC and allow you to install the camshafts in the same position as noted during the disassembly.

    Rotate the crankshaft clockwise 90 degrees so the crankshaft contacts the special tool.

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59. If necessary, replace any tappets with the correct tappets selected during the valve clearance check and lubricate with clean engine oil.

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60. NOTE: The exhaust camshaft rear bearing cap must be secured within 10 minutes of silicone sealant application. If the bearing cap is not secured within 10 minutes, the gasket maker must be removed and the sealing area cleaned.
    NOTE: Do not allow gasket maker to enter the camshaft bearing journal. If gasket maker is applied to the camshaft bearing journal, the journal and sealing area must be cleaned.

    Apply a 1 mm bead of gasket maker.

    Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

    Courtesy of FORD MOTOR COMPANY

61. NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
    NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.
    NOTE: Wipe off any excess sealant from the fuel injection pump housing sealing surface of the cylinder head and rear camshaft cap.
    NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil.
    • Lubricate with clean engine oil and install the camshafts, caps and bolts.
    • Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight.
    • Tighten 2 turns at a time in the sequence shown below in 2 stages.

      Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 142 lb.in (16 Nm)

    Fig 9: Camshaft Bearing Cap Bolts Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
62. • Lubricate the camshaft journals with clean engine oil.
    • Install the front camshaft bearing cap and the bolts and tighten in 2 stages.

      Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 142 lb.in (16 Nm)

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63. Install the VCT oil control solenoids and the bolts.

    Torque: 89 lb.in (10 Nm)

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

    Install Special Service Tool: 303-1565 Alignment Tool, Camshaft.

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65. NOTE: The exhaust and intake VCT units are not interchangeable. The exhaust VCT unit can be identified by the 3 allen head bolts on the face. The intake VCT unit has 4 torx head bolts.
    NOTE: Do not tighten the VCT unit bolts at this time.

    Install the VCT units and the bolts finger-tight.

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66. Install the tensioner arm, timing chain, timing chain guide and the bolts.

    Torque: 89 lb.in (10 Nm)

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    NOTE: If equipped with aluminum timing chain tensioner.
    NOTE: If the timing chain tensioner plunger is not pinned in the compressed position, follow the next step.
67. Reset the timing chain tensioner.
    1. Position the timing chain tensioner in a soft-jawed vise.
    2. Spread the ends of the ratchet wire clip apart.
    3. Using the soft-jawed vise, compress the plunger to the reset position.
    4. Install a locking pin in the 2 holes of the timing chain tensioner body to hold the plunger in place.

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68. NOTE: If equipped with aluminum timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.
    1. Install the timing chain tensioner and the bolts.

       Torque: 89 lb.in (10 Nm)

    2. Remove the locking pin.

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    NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
69. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

    Using the edge of a vise, compress the timing chain tensioner plunger.

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70. Using a small pick, push back and hold the ratchet mechanism.

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

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72. Install a locking pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

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73. NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

    Install the timing chain tensioner and the bolts.

    Torque: 89 lb.in (10 Nm)

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74. NOTE: If equipped with cast iron timing chain tensioner.

    Remove the locking pin.

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75. NOTE: Use an open-ended wrench to prevent the component from turning.

    Tighten the exhaust VCT unit bolt in 2 stages.

    Torque: Stage 1: 30 lb.ft (40 Nm) | Stage 2: 60 deg.

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76. NOTE: Use an open-ended wrench to prevent the component from turning.

    Tighten the intake VCT unit bolt in 2 stages.

    Torque: Stage 1: 30 lb.ft (40 Nm) | Stage 2: 60 deg.

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77. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the silicone sealant must be removed and the sealing area cleaned.

    Apply silicone sealant.

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

    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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78. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the silicone sealant must be removed and the sealing area cleaned.

    Apply beads of silicone sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas.

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

    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

    Courtesy of FORD MOTOR COMPANY

79. Install the engine front cover and the fasteners and tighten in the sequence shown below.

    Torque: Bolts 1 - 3: 35 lb.ft (48 Nm) Bolts 4 - 22: 89 lb.in (10 Nm)

    Fig 10: Engine Front Cover Fastener Tightening Sequence

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

    Lubricate with clean engine oil and using the special tool, install the crankshaft front seal. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.

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81. Lubricate the crankshaft pulley with clean engine oil.

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82. Install the crankshaft pulley.

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

    Install an M6 bolt.

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84. NOTE: The crankshaft must remain in the 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 universal pulley holder and the bolt should be installed using hand tools only.
    NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).
    NOTE: A small amount of oil applied to the crankshaft bolt threads will ease the tightening process.

    Using a universal pulley holder, tighten the crankshaft pulley.

    Torque: Stage 1: 74 lb.ft (100 Nm) | Stage 2: 180 deg.

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85. Remove the M6 bolt.

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86. NOTE: Do not tighten the CKP sensor bolts at this time.

    Install the CKP sensor and the bolts finger-tight.

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87. Install the Special Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.

    Torque: 62 lb.in (7 Nm)

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88. Remove Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.

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89. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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90. Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft.

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91. Install the engine plug bolt.

    Torque: 177 lb.in (20 Nm)

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92. Install the camshaft drive adapter.

    Torque: 46 lb.ft (63 Nm)

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93. NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of gasket maker application. If the bearing cap is not secured within 10 minutes, the gasket maker must be removed and the sealing area cleaned.

    Apply a 1 mm bead of gasket maker.

    Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

    Courtesy of FORD MOTOR COMPANY

94. NOTE: Wipe off any excess gasket maker from the vacuum pump sealing surface of the cylinder head and camshaft cap.

    Install camshaft rear bearing cap and the bolts.

    Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 142 lb.in (16 Nm)

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95. NOTE: Do not use compressed air or the Fuel Injector Brush to clean the tip of the fuel injectors. Failure to follow this instruction may result in damage to the fuel injectors.
    NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

    Using the special tool, clean the fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.

    Courtesy of FORD MOTOR COMPANY

96. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    1. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
    2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.

       Make sure that new lower fuel injector Teflon® seals are installed. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

    3. Using the special tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors.

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97. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
    NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
    1. Some massaging of the Teflon® seal with your fingers before the special tool is installed will aid in installing the special tool.
    2. Position the Teflon® seal sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® seal sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
    3. Once the special tool is installed, check and make sure the Teflon® seal is in the sizing portion of the special tool. After one minute, turn the special tool back 180 degrees and remove.

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98. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    1. Install the fuel injector seal.
    2. Install the fuel injector O-ring seal.
    3. Install the fuel injector seal.

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99. NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.
    NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

    Install the fuel injectors in the fuel rail.

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100. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
     • NOTE: No sudden impact force is allowed.
       NOTE: Make sure that new bolts are installed.

       Press the fuel rail down into the cylinder head injector bores by hand, then install and hand start fuel rail bolts 3 and 4.

     • Release the force before tightening.
     • Install the remaining fuel rail bolts. Tighten all of the fuel rail bolts in the sequence shown below and in the following 5 stages.

       Torque: Stage 1: Tighten to: : 89 lb.in (10 Nm) | Stage 2: Release the torque to: : 0 lb.in (0 Nm) | Stage 3: Wait 5s. | Stage 4: Tighten to: : 124 lb.in (14 Nm) | Stage 5: Tighten an additional: : 30 deg.

     Fig 11: Fuel Rail Bolts Tightening Sequence

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101. • Connect the fuel injectors and FRP sensor electrical connectors.
     • Install the fuel rail shield.

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102. Inspect and replace the crankcase vent separator gasket, if damaged.

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103. Install the crankcase vent separator and the bolts.

     Torque: 89 lb.in (10 Nm)

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104. • NOTE: The forward KS must be installed in the 6 o'clock position and the rearward KS must be installed in the 3 o'clock position as shown below in the graphic. Failure to follow these instructions may result in damage to the engine.

       Install the KS in their original position and install the bolts.

       Torque: 177 lb.in (20 Nm)

     • Connect the KS electrical connectors.

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105. Install a new coolant outlet gasket.

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106. Install the coolant outlet and the bolts.

     Torque: 89 lb.in (10 Nm)

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107. Connect the coolant tube and the retainers. Use the General Equipment: Hose Clamp Remover/Installer

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108. NOTE: Installation of new seals is only required if damaged seals were removed during valve cover removal.

     If removed, using the special tools, install the VCT oil control solenoid seals. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

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109. Install a new valve cover gasket.

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110. Apply a 5.5 mm bead of silicone sealant.

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

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111. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the silicone sealant must be removed and the sealing area cleaned.

     Install the valve cover and tighten the fasteners in the sequence shown below.

     Torque: 89 lb.in (10 Nm)

     Fig 12: Valve Cover Fasteners Tightening Sequence

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112. Inspect the ignition coil-on-plug assembly for cracks, rips, or tears. Replace any damaged coil-on-plug assemblies.

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113. Install the ignition coil-on-plugs and the fasteners.

     Torque: 53 lb.in (6 Nm)

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114. Install a new CHT sensor.

     Torque: 97 lb.in (11 Nm)

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115. NOTE: The fuel injection cam lobe must be positioned at zero lift before installing the high-pressure fuel pump drive unit.

     Rotate the crankshaft to position the camshaft at zero lift.

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116. Inspect and replace the high-pressure fuel pump drive unit gasket, if damaged.

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117. Install the high-pressure fuel pump drive unit and the stud bolts and tighten in 2 stages.

     Torque: Stage 1: 133 lb.in (15 Nm) | Stage 2: 60 deg.

     Courtesy of FORD MOTOR COMPANY

118. Inspect the high-pressure fuel pump tappet for flat spots or scoring, especially in the indicated areas. If any damage is found, inspect the high-pressure fuel pump and the high-pressure fuel pump tappet drive lobe. Install a new component as necessary.

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119. • Lubricate the high-pressure fuel pump tappet with clean engine oil.
     • Install the high-pressure fuel pump tappet.

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120. NOTE: Lubricate the fuel injection pump O-ring seal with clean engine oil.

     Install a new fuel injection pump O-ring seal.

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121. NOTE: Install new bolts.

     Install the fuel injection pump and alternately tighten each bolt one complete revolution until seated in 2 stages.

     Torque: Stage 1: 44 lb.in (5 Nm) | Stage 2: 55 deg.

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122. Install the fuel injection pump bracket and the bolts.

     Torque: 150 lb.in (17 Nm)

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123. NOTE: Install a new fuel tube.
     • Install the fuel tube, nut and the bolt finger-tight.
     • Install the flare nuts finger-tight.

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124. Tighten the flare nuts in 2 stages.

     Torque: Stage 1: 133 lb.in (15 Nm) | Stage 2: 30 deg.

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125. 1. Tighten the bolt.

        Torque: 89 lb.in (10 Nm)

     2. Tighten the nut.

        Torque: 150 lb.in (17 Nm)

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126. Inspect and replace the brake vacuum pump gasket, if damaged.

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127. Install the brake vacuum pump and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

128. Install the ground strap and the bolt.

     Torque: 18 lb.ft (25 Nm)

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129. Inspect and replace the thermostat housing gasket, if damaged.

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130. 1. Install the thermostat housing the bolts.

        Torque: 89 lb.in (10 Nm)

     2. Install the generator stud.

        Torque: 80 lb.in (9 Nm)

     Courtesy of FORD MOTOR COMPANY

131. Install and lubricate the coolant pump O-ring seal with clean engine coolant.

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132. Install the coolant pump and the bolts.

     Torque: 89 lb.in (10 Nm)

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133. 1. Install the coolant pump pulley and the bolts finger-tight.
     2. Install the accessory drive belt tensioner and the bolts.

        Torque: 18 lb.ft (25 Nm)

     3. Install the generator, nut and the bolt.

        Torque: 18 lb.ft (25 Nm)

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134. 1. Install the tool and release the tension on the accessory drive belt tensioner.
     2. Install the accessory drive belt.
     3. Release the tool and remove.

     Courtesy of FORD MOTOR COMPANY

135. Tighten the coolant pump pulley bolts.

     Torque: 177 lb.in (20 Nm)

     Courtesy of FORD MOTOR COMPANY

136. Install the studs and the turbocharger gasket.

     Torque: 150 lb.in (17 Nm)

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137. Install the turbocharger and the nuts.

     Torque: 37 lb.ft (50 Nm)

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138. Position the turbocharger vacuum valve and install the nuts.

     Torque: 89 lb.in (10 Nm)

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139. Install the heat shield, nuts and the bolt finger-tight.

     Courtesy of FORD MOTOR COMPANY

140. 1. Tighten the nuts.

        Torque: 37 lb.ft (50 Nm)

     2. Tighten the bolt.

        Torque: 89 lb.in (10 Nm)

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141. NOTE: Do not reuse the turbocharger oil filter, a new part must be installed.

     Install a new turbocharger oil supply filter.

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142. • Install new sealing washers.
     • Lubricate and install the new turbocharger oil supply tube O-ring seal with clean engine oil.

     Courtesy of FORD MOTOR COMPANY

143. NOTE: The oil feed hose must be fully seated prior to fastener rundown.
     1. Install the turbocharger oil supply tube and the bolt.

        Torque: 89 lb.in (10 Nm)

     2. Tighten the bolt.

        Torque: 18 lb.ft (25 Nm)

     Courtesy of FORD MOTOR COMPANY

144. • Install a new turbocharger O-ring seal and lubricate with clean engine oil.
     • Install a new turbocharger gasket.

     Courtesy of FORD MOTOR COMPANY

145. NOTE: The oil drain tube must be fully seated prior to fastener rundown.

     Install the turbocharger-to-cylinder block oil return tube and the bolts.

     Torque: 89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

146. • Inspect a the O-ring seals, replace if damaged.
     • Discard the washers.

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147. • Lubricate the O-ring seals with engine coolant.
     • Install new washers.

     Courtesy of FORD MOTOR COMPANY

148. 1. Fit the O-ring end of the turbocharger coolant tubes to the turbocharger. The lower coolant inlet tube goes into the turbocharger first. Install the bolt.

        Torque: 89 lb.in (10 Nm)

     2. Install the bolt for the turbocharger coolant inlet tube.

        Torque: 27 lb.ft (37 Nm)

     3. Connect the turbocharger coolant outlet tube to the coolant outlet. Use the General Equipment: Hose Clamp Remover/Installer

     Courtesy of FORD MOTOR COMPANY

149. Connect the radiator hose to the thermostat housing. Use the General Equipment: Hose Clamp Remover/Installer

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150. Install the coolant hose and connect. Use the General Equipment: Hose Clamp Remover/Installer

     Courtesy of FORD MOTOR COMPANY

151. Install the high-pressure fuel pump drive unit cover and the retainer.

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152. 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.

     Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be reused.

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153. • Install the intake manifold.
     • Attach the KS electrical connector retainers to the intake manifold.
     • Connect the PCV tube quick release coupling.

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154. Position the intake manifold and install the bolts.

     Torque: 177 lb.in (20 Nm)

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155. Install the nut on the coolant tube stud.

     Torque: 177 lb.in (20 Nm)

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156. Inspect the coolant tube O-ring seal and replace if necessary.

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157. Lubricate the coolant tube O-ring seal with clean engine coolant.

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158. 1. NOTE: The coolant tube must be fully seated prior to tighten the bolt.

        Install the coolant tube and bolt.

        Torque: 97 lb.in (11 Nm)

     2. Install the coolant tube bolt.

        Torque: 22 lb.ft (30 Nm)

     Courtesy of FORD MOTOR COMPANY

159. Install a new O-ring seal and lubricate with clean engine coolant.

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160. 1. Install the coolant tube.
     2. Install the coolant tube bolt.

        Torque: 89 lb.in (10 Nm)

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161. • Connect the crankcase vent tube to the valve cover.
     • Attach the crankcase vent tube retainer.

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162. • Install the oil level indicator.
     • Install the EVAP canister purge valve and the bolt.

       Torque: 71 lb.in (8 Nm)

     • Connect the EVAP canister purge valve quick release coupling.

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163. • Install the engine wiring harness and attach the wiring harness retainer.
     • Connect the ignition coil-on-plugs and VCT oil control solenoid sensor electrical connectors.
     • Connect the CMP sensor and EVAP canister purge valve electrical connectors.

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164. • Attach the wiring harness retainers.
     • Connect the throttle body and MAPT electrical connectors.

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165. • Attach the wiring harness retainer.
     • Connect the ECT sensor electrical connector.
     • Connect and attach the fuel injector harness electrical connector.

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     10-Speed Automatic Transmission - 10R80 

166. Attach the wiring harness retainer.

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     6-Speed Manual Transmission - MT82/10-Speed Automatic Transmission - 10R80 

167. Inspect and replace the oil filter adapter gasket, if damaged.

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168. • Install the oil filter adapter and the bolts.

       Torque: 18 lb.ft (25 Nm)

     • Connect the oil pressure switch electrical connector.

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169. • Install the fuel supply tube and attach the retainer.
     • Connect the fuel supply tube quick release coupling to the high-pressure fuel pump. Refer to: Quick Release Coupling .
     • Attach the fuel supply tube to the intake manifold retainer.

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170. • Install the high-pressure fuel pump cover.
     • Attach the wiring harness retainers.
     • Connect the high-pressure fuel pump, fuel supply tube pressure switch and crankcase vent tube wiring harness electrical connectors.

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171. • Attach the wiring harness retainers.
     • Connect the CHT sensor electrical connector.

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172. • Position the ground wire harness and install the bolt.

       Torque: 177 lb.in (20 Nm)

     • Attach the wiring harness retainer.

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173. • Attach the wiring harness retainers.
     • Connect the CKP and vacuum valve electrical connectors.

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174. Install the LH engine mount bracket, stud bolt and the bolts.

     Torque: 46 lb.ft (63 Nm)

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175. Install the RH engine mount bracket, stud bolt and the bolts.

     Torque: 46 lb.ft (63 Nm)

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176. Install the A/C compressor mounting bracket and the bolts.

     Torque: 35 lb.ft (48 Nm)

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177. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

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178. Remove engine from the mounting stand. Use the General Equipment: Mounting Stand

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     6-Speed Manual Transmission - MT82 

179. NOTE: Special bolts are used for installation. Do not use standard bolts.
     • Install the flywheel and the new bolts finger-tight.
     • Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
     • Tighten the bolts in sequence shown below in 3 stages.

       Torque: Stage 1: 37 lb.ft (50 Nm) | Stage 2: 59 lb.ft (80 Nm) | Stage 3: 83 lb.ft (112 Nm)

     Fig 13: Flywheel Bolts Tightening Sequence

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180. Using the Clutch Alignment tool, position the clutch disc on the flywheel. Use the General Equipment: Clutch Alignment Tool

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

     Using the Clutch Alignment tool, position the clutch pressure plate on the flywheel and install the clutch pressure plate bolts. Use the General Equipment: Clutch Alignment Tool

     Torque: 26 lb.ft (35 Nm)

     Courtesy of FORD MOTOR COMPANY

     10-Speed Automatic Transmission - 10R80 

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

       Install the flexplate and the new bolts finger-tight.

     • Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
     • Tighten the bolts in sequence shown below in 3 stages.

       Torque: Stage 1: 37 lb.ft (50 Nm) | Stage 2: 59 lb.ft (80 Nm) | Stage 3: 83 lb.ft (112 Nm)

Fig 14: Flywheel Bolts Tightening Sequence

Courtesy of FORD MOTOR COMPANY