Part 3
EngineAssembly (Steps 62-90)
62. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
NOTE: Spark plug tube seal installation shown, VCT seal installation similar.
Using the special tools, install new VCT solenoid and/or spark plug tube seals.
63. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
64. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
65. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
66. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
67. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 7 Nm (62 lb-in).
68. NOTE: Engine without oil cooler shown, engine with oil cooler similar.
Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts.
^ Tighten the large bolt to 57 Nm (42 lb-ft).
^ Tighten the small bolt to 10 Nm (89 lb-in).
69. CAUTION: A new oil cooler must be installed or severe damage to the engine may occur.
If equipped, install a new oil cooler, new gaskets and the 6 bolts.
^ Tighten to 10 Nm (89 lb-in).
70. NOTE: Apply thread sealant with PTFE to the engine oil pressure (EOP) switch threads.
Install the EOP switch.
^ Tighten to 18 Nm (13 lb-ft).
71. Install the crankshaft position (CKP) sensor and install the bolt.
^ Tighten to 10 Nm (89 lb-in).
72. Install LH camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).
73. Install and connect the cylinder head temperature (CHT) sensor jumper harness.
74. Using new gaskets, install the lower intake manifold and the 10 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
75. Using a new gasket, install the thermostat housing and the 3 bolts.
^ Tighten to 10 Nm (89 lb-in).
76. CAUTION: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: The upper and lower O-ring seals are not interchangeable.
Install new fuel injector O-ring seals.
^ Remove the retaining clips and separate the fuel injectors from the fuel rail.
^ Remove and discard the O-ring seals.
^ Install new O-ring seals and lubricate with clean engine oil.
^ Install the fuel injectors and the retaining clips onto the fuel rail.
77. Install the fuel rail and injectors as an assembly and install the 4 bolts.
^ Tighten to 10 Nm (89 lb-in).
All wheel drive (AWD) vehicles
78. Install the catalytic converter bracket and the 2 bolts.
^ Tighten to 48 Nm (35 lb-ft).
All vehicles
79. Install the RH CMP sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).
80. Install the engine lifting eye and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).
81. Install the cover and the pin-type retainer.
82. Install the LH cylinder block drain plug.
^ Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
83. Install the RH cylinder block drain plug or, if equipped, the block heater.
^ Tighten to 40 Nm (30 lb-ft).
84. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
85. CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten to 20 Nm (15 lb-ft).
Front wheel drive (FWD) vehicles
86. Install the RH exhaust manifold heat shield and the 3 bolts.
^ Tighten to 14 Nm (10 lb-ft).
87. Install the 4 new RH catalytic converter-to-exhaust manifold studs.
^ Tighten to 25 Nm (18 lb-ft).
88. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
^ Tighten to 40 Nm (30 lb-ft).
All vehicles
89. Install 6 new LH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
90. CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten to 20 Nm (15 lb-ft).
