Part 5

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.

132. Install the wiring harness retainer bolt on the rear of the LH cylinder head.
- Tighten to 10 Nm (89 lb-in).





133. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

134. Connect the LH camshaft VCT solenoid electrical connector.





135. Connect the 3 LH coil-on-plug electrical connectors.





136. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.





137. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.





138. Connect the LH CMP sensor electrical connector.





139. Connect the CHT sensor electrical connector.





140. Connect the 6 fuel injector electrical connectors (3 shown).





141. Install the ground cable and the bolt.
- Tighten to 10 Nm (89 lb-in).





142. Connect the KS electrical connector.





143. Connect the RH CMP sensor electrical connector.





144. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

145. Connect the 3 RH coil-on-plug electrical connectors.





146. Connect the RH VCT solenoid electrical connector.





FWD vehicles

147. Connect the RH CMS electrical connector.





All vehicles

148. Connect the Power Steering Pressure (PSP) switch electrical connector.





149. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Using a new gasket, install the upper intake manifold and the 6 bolts.

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





150. Install the upper intake manifold support bracket and the 2 bolts (1 shown).
- Tighten to 10 Nm (89 lb-in).





151. Connect the RH HO2S electrical connector.





152. Attach the wiring harness retainers to the upper intake manifold.





153. Connect the Throttle Body (TB) electrical connector.





154. Connect the PCV hose to the PCV valve.





155. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.

156. If equipped, connect the block heater electrical connector and install the heat shield.





157. Install the Engine Lift Eye on the LH cylinder head.





158. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.





159. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.





160. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





161. Install the crankshaft sensor ring.





162. Install the flexplate and the 8 bolts.
- Tighten to 80 Nm (59 lb-ft).