Part 2 of 2

45. Remove the retaining pin.





46. Install the engine front cover and engine front cover gasket.
(1) Position a new engine front cover gasket and the engine front cover on the dowels.
(2) Install the two engine front cover stud bolts.
(3) Install the engine front cover bolt.
(4) Install the engine front cover socket head cap screw.





47. Use (A) Front Crankshaft Seal Replacer (spacer), (B) Front Crankshaft Seal Installer/Aligner and (D) Vibration Damper Remover Adapter to install the (C) front crankshaft oil seal.

NOTE: Lubricate parts with engine oil before assembly.





48. Apply a bead of sealant to the keyway in the crankshaft damper and use Vibration Damper Remover Adapter to position and install the crankshaft damper.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A1.





49. Install the crankshaft damper bolt.





50. Install the crankshaft pulley.
(1) Position the crankshaft pulley.
(2) Install the four bolts.

NOTE: The crankshaft pulley position on the crankshaft damper was marked before removal; return it to the same position.

51. Install the camshaft synchronizer.





52. Position a new (A) water pump housing gasket and the (B) water pump onto the studs and install the (C) water pump stud bolt.





53. Install the four (A) water pump stud nuts and the four (B) water pump bolts.





54. Install the wafer pump pulley.
(1) Position the water pump pulley.
(2) Install the four bolts.





55. On early models, temporarily install two locator dowels.





56. On late models, temporarily install two locator dowels.





57. Clean and apply sealant to the oil pan sealing areas indicated and install the oil pan rear seal.
(1) On early models, apply sealer to the rear main bearing cap.
(2) Install the oil pan rear seal.
(3) Apply sealer to oil pan mating surface.
- Use Metal Surface Cleaner F4AZ-l9A536-RA or equivalent meeting Ford specification WSE-MSB392-A.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A1.

NOTE: If the oil pan is not installed within four minutes, remove the sealer and reapply.





58. Clean and apply sealant to the oil pan sealing areas indicated and install the oil pan rear seal.
(1) On late models, apply sealer to the rear main bearing cap.
(2) Install the oil pan rear seal.
(3) Apply sealer to the oil pan mating surface.
- Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A.-Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-Al.

NOTE: If the oil pan is not installed within four minutes, remove the sealer and reapply.





59. Position the oil pan and start the 13 oil pan to cylinder block bolts.





60. Replace the two locator dowels with the two remaining oil pan to cylinder block bolts.





61. Tighten the 15 oil pan to cylinder block bolts in the sequence indicated.

NOTE: Make sure to tighten the oil pan bolts in two steps.





62. Tighten the 15 oil pan to cylinder block bolts in the sequence indicated.





63. Install the oil pan plug.





64. Install the oil pressure sensor.





65. Install a new oil bypass filter.





66. Install the LH valve cover.
(1) Position the LH valve cover.
(2) Install the three bolts.
(3) Install the two stud bolts.

NOTE: Inspect the LH valve cover gasket for damage. Replace if necessary.





67. Install the RH valve cover.
(1) Position the RH valve cover.
(2) Install the two bolts.
(3) Install the three stud bolts.

NOTE: Inspect the RH valve cover gasket for damage. Replace if necessary.





68. Install a new (A) RH exhaust manifold gasket and position the (B) RH exhaust manifold. Loosely install the four (C) RH exhaust manifold bolts and the two (D) RH exhaust manifold stud bolts.





69. Tighten the exhaust manifold bolts in the sequence indicated.





70. Install a new (A) LH exhaust manifold gasket and position the (B) LH exhaust manifold. Loosely install the three (C) LH exhaust manifold bolts and install the three (D) LH exhaust manifold stud bolts.





71. Tighten the exhaust manifold bolts in the sequence Indicated.





72. Install the oil level indicator tube.
(1) Install a new oil level indicator tube O-ring
(2) Position the (A) oil level indicator tube and install the (B) oil level indicator tube bracket nut.





73. Install the valve tappets.
(1) Install the valve tappets.
(2) Install the tappet guide plates and retainers.
(3) Install the four tappet guide plate bolts.

NOTE: Lubricate the valve tappets prior to installing.








74. Refer to the illustration for intake manifold sealing components.





75. Install the lower intake manifold front and rear end seals.
(1) Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A1 0
(2) Install the lower intake manifold front and rear end seals.





76. Install the intake manifold gaskets.





77. Position the lower intake manifold.
(1) Apply a bead of sealant to the lower intake manifold mounting at the points indicated.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A1.
(2) Position the lower intake manifold.

NOTE: The lower intake manifold must be installed within four minutes of applying the sealant.





78. Install the six long lower intake manifold bolts.

NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.





79. Install the eight short lower intake manifold bolts.





80. Tighten tile lower intake manifold belts in the sequence shown.

NOTE: Make sure to tighten the lower intake manifold bolts in two steps.





81. Tighten the lower intake manifold bolts in the sequence shown.





82. Install the following sensors:
- Engine coolant temperature (ECT) sensor (A).
- Water temperature indicator sender unit (B).





83. Install the IMRC actuator brackets.
(1) Connect the linkages.
(2) Position the brackets.
(3) Install the two bolts on each bracket.
(4) Connect the vacuum hoses.





84. Connect the water pump bypass hose.
(1) Position the water pump bypass hose.
(2) Position the hose clamp.





85. Install the EGR valve to exhaust manifold tube.
(1) Position the EGR valve to exhaust manifold tube.
(2) Install the EGR valve tube lower fitting.
(3) Install the EGR valve tube upper fitting.





86. Install the generator bracket.
(1) Position the generator bracket.
(2) Install the two long bolts.
(3) Install the short bolts.





87. Install the idler pulley.
(1) Position the idler pulley.
(2) Install the bolt.





88. Install the generator.
(1) Position the generator.
(2) Install the two nurse.
(3) Install the bolt.