Part 3

Engine

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Special Tool(s) (Part 3):

Material (Part 1):

Material (Part 2):

Engine - Upper End (Part 1):

Engine - Upper End (Part 2):

Engine - Upper End (Part 3):

Engine - Front End (Part 1):

Engine - Front End (Part 2):

Engine - Lower End (Part 1):

Engine - Lower End (Part 2):

Assembly (Steps 67-99)
67. Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
68. Lubricate the balance shaft journals with clean engine oil.





69. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
70. Position the balance shaft on the journals.

71. NOTE: It may be necessary to use an inspection mirror to see the marks.

Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.





72. NOTE: Install the balance shaft bearing caps in their original locations.

Install the bolts and tighten in the sequence shown.
^ Tighten to 10 Nm (89 lb-inch).





73. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

CAUTION: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of Silicone Gasket and Sealant along the cylinder head-to-cylinder block surface at the locations shown.





74. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.





75. Tighten the engine front cover fasteners in sequence in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).











76. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-inch).





77. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Position the coolant pump and install the bolts loosely.
^ Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.





78. Tighten the 4 coolant pump bolts.
^ Tighten to 25 Nm (18 lb-ft).





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





80. Using the special tools, install the crankshaft seal into the engine front cover.





81. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply Silicone Gasket and Sealant to the
^ Woodruff key slot on the crankshaft pulley.





82. Using the special tool, install the crankshaft pulley.





83. Tighten the new crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 lb-ft).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.





84. Position the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-inch).





85. Position the accessory drive belt tensioner and install the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).





86. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
^ Tighten to 25 Nm (18 lb-ft).





87. NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.
^ Tighten to 24 Nm (18 lb-ft).





88. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: Clean and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts and the nut.
^ Tighten the bolts to 25 Nm (18 lb-ft).
^ Tighten the nut to 48 Nm (35 lb-ft).





89. NOTE: RH shown, LH similar.

Install 20 new exhaust manifold-to-cylinder head studs.
^ Tighten to 12 Nm (9 lb-ft).





90. Position 2 new gaskets, the LH exhaust manifold and tighten the 10 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).





91. Position the exhaust manifold heat shield and install the 3 bolts.
^ Tighten to 14 Nm (10 lb-ft).





92. CAUTION: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

CAUTION: Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator damage.

NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

Position the engine support insulator bracket and install 3 new bolts in 2 stages.
^ Stage 1: Tighten to 30 Nm (22 lb-ft).
^ Stage 2: Tighten an additional minimum of 60 degrees.





93. Position 2 new gaskets, the RH exhaust manifold and tighten the 10 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).





94. Position the exhaust manifold heat shield and install the 2 bolts.
^ Tighten to 14 Nm (10 lb-ft).





95. CAUTION: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

Position the engine support insulator bracket and install 3 new bolts in 2 stages.
^ Stage 1: Tighten to 30 Nm (22 lb-ft).
^ Stage 2: Tighten an additional minimum of 60 degrees.





96. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging.

97. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply a bead of Silicone Gasket and Sealant in 2 places where the engine front cover meets the cylinder head.





98. Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
^ Tighten to 10 Nm (89 lb-inch).





99. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging.