Part 2
Cylinder HeadSpecial Tool(s) (Part 1):
Special Tools (Part 2):
Material (Part 1):
Material (Part 2):
Installation (Steps 39-77)
39. 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).
40. Install the 4 front oil pan bolts in the sequence shown in 2 stages:
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten an additional 60 degrees.
41. 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.
42. 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 in 2 places where the engine front cover meets the cylinder head.
43. CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
Position the RH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
^ Tighten to 10 Nm (89 lb-inch).
44. 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.
45. 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 in 2 places where the engine front cover meets the cylinder head.
46. CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
Position the LH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
^ Tighten to 10 Nm (89 lb-inch).
47. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
48. Use the special tools to install a new crankshaft front seal into the engine front cover.
49. 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.
50. Use the special tool to install the crankshaft pulley.
51. 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.
52. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the LH camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
53. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the RH CMP sensor and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
54. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Position the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
55. Connect the intake manifold vacuum tube to the valve cover stud and the support bracket.
56. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
^ Tighten to 25 Nm (18 lb-ft).
57. Position the oil level indicator and tube and install the bolt.
^ Install a new O-ring seal and lubricate with clean engine oil prior to installation.
^ Tighten to 10 Nm (89 lb-inch).
58. Install the oil level indicator and tube front bolt.
^ Tighten to 25 Nm (18 lb-ft).
59. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.
NOTE: LH shown, RH similar.
Install the 8 ignition coils and the 8 bolts.
^ Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
^ Tighten to 6 Nm (53 lb-inch).
60. Position the electrical harness on the engine assembly.
61. Connect the engine oil pressure (EOP) switch electrical connector.
62. Connect the 2 engine wiring harness retainers to the LH valve cover studs.
63. Connect the engine wiring harness position retainers to the front of the RH valve cover.
64. Connect the engine wiring harness position retainers to the front of the LH valve cover and the LH CMP sensor electrical connector.
65. Install the LH radio ignition interference capacitor and the stud bolt.
^ Tighten to 25 Nm (18 lb-ft).
66. Connect the cylinder head temperature (CHT) sensor electrical connector.
67. NOTE: RH shown, LH similar.
Connect the 8 ignition coil electrical connectors.
68. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
69. Connect the RH VCT solenoid electrical connector.
70. Install the RH radio ignition interference capacitor and the stud bolt.
^ Tighten to 25 Nm (18 lb-ft).
71. Connect the RH CMP sensor electrical connector.
72. CAUTION: The engine support insulator bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. 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.
NOTE: Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
Position the RH engine support insulator bracket, 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.
73. NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to remove it.
Using the special tool, install the engine cooling fan onto the coolant pump pulley.
^ Tighten to 55 Nm (41 lb-ft).
74. Install the special tool.
75. Using a suitable floor crane, remove the engine from the engine stand.
76. Install the flexplate or flywheel and the 8 bolts in the sequence shown.
^ Tighten to 80 Nm (59 lb-ft).
77. Install the engine.