Part 2

Engine















Engine Upper











Engine Upper - LH Cylinder Head











Engine Upper - RH Cylinder Head











Engine Front

NOTE: Early build shown, late build similar.











Lower Engine Block (View 1)











Lower Engine Block (View 2)









NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTICE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine.

NOTICE: Early build vehicle (built before January 19, 2009) cooling systems are filled with Motorcraft(R) Premium Gold Engine Coolant. Late build vehicle (built on or after January 19, 2009) cooling systems are filled with Motorcraft(R) Specialty Green Engine Coolant. Mixing coolant types degrades the corrosion protection of the coolant. Do not mix coolant types. Failure to follow these instructions may result in engine or cooling system damage.

NOTICE: Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

34. Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).





35. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown.
- Tighten the large bolts (1-14) to 24 Nm (18 lb-ft).

- Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).





36. Install the A/C compressor mounting stud and nut.
- Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).





37. Install the coolant pump and the 8 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





38. Install the Knock Sensor (KS) and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).





39. NOTE: Apply clean engine coolant to the O-ring seals prior to installation.

Using new O-ring seals, install the coolant inlet tube.





40. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 35 Nm (26 lb-ft).

- Stage 3: Tighten 90 degrees.

- Stage 4: Tighten 90 degrees.

- Stage 5: Tighten 90 degrees.





41. Install the bolt.
- Tighten to 10 Nm (89 lb-in).





42. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 35 Nm (26 lb-ft).

- Stage 3: Tighten 90 degrees.

- Stage 4: Tighten 90 degrees.

- Stage 5: Tighten 90 degrees.





43. Install the bolt.
- Tighten to 10 Nm (89 lb-in).





44. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

Position the crankshaft dowel pin in the 9 o'clock position.





45. NOTE: The valve tappets must be installed in their original positions.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

NOTE: LH shown, RH similar.

Install the valve tappets.





46. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

NOTE: Coat the camshafts with clean engine oil prior to installation.

Position the camshafts onto the RH cylinder head in the neutral position as shown.





47. NOTICE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.

Install the 8 camshaft caps and the 16 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





48. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

NOTE: Coat the camshafts with clean engine oil prior to installation.

Position the camshafts onto the LH cylinder head in the neutral position as shown.





49. NOTICE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.

Install the 8 camshaft caps and the 16 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





50. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to Valve Clearance Check Adjustments.





Engines equipped with early build RH timing chain guides

51. Install the RH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





Engines equipped with late build/replacement RH timing chain guides

52. Install the RH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





All vehicles

53. Install the RH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





54. NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Rotate the RH camshafts to the top dead center position and install the Camshaft Holding Tool on the flats of the camshafts.





55. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
- Align the colored links with the timing marks.





56. Position the RH secondary timing assembly onto the camshafts.





57. Install 2 new bolts and the original washer. Tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 10 Nm (89 lb-in).

- Stage 4: Tighten 90 degrees.





58. Remove the lockpin from the RH secondary timing chain tensioner.





59. Install the LH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





60. NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.





61. Assemble the LH Variable Camshaft Timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
- Align the colored links with the timing marks.





62. Position the LH secondary timing assembly onto the camshafts.





63. Install 2 new bolts and the original washer. Tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 10 Nm (89 lb-in).

- Stage 4: Tighten 90 degrees.





64. Remove the lockpin from the LH secondary timing chain tensioner.





65. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).





66. Install the crankshaft timing chain sprocket.