Part 3
Engine
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, may cause engine failure.
NOTE: 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.
NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1G372 BA) and late build engines are built with engine code (1G372 CA).
All vehicles
92. NOTE: The 2 VCT oil control solenoids are removed for clarity.
Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
- Make sure the secondary timing chain is centered on the timing chain tensioner guides.
All engines
93. Install the upper LH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
94. Rotate the crankshaft clockwise 60 degrees to the Top Dead Center (TDC) position (crankshaft dowel pin at 11 o'clock).
95. Install the crankshaft timing chain sprocket with timing dot mark out.
96. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
97. Install the lower LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
98. Install the primary timing chain tensioner arm.
99. Reset the primary timing chain tensioner.
- Release the ratchet detent.
- Using a soft-jawed vise, compress the ratchet plunger.
- Align the hole in the ratchet plunger with the hole in the tensioner housing.
- Install a suitable lockpin.
100. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.
Install the primary tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the lockpin.
101. As a post-check, verify correct alignment of all timing marks.
- There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
- There is 35 links in between RH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
102. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Install the LH intake VCT oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
103. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Install the RH intake VCT oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
104. Remove the RH Camshaft Holding Tool.
105. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
106. Remove the LH Camshaft Holding Tool.
107. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
108. NOTE: Use Spindle Bearing Installer 205-149 to install the seal.
If removed, using the Spindle Bearing Installer, install the front cover radial seal from the rear side of the front cover.
109. NOTICE: Failure to use Motorcraft(R) High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
NOTICE: Do not expose the Motorcraft(R) High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow these instructions may cause engine oil leakage.
NOTE: The engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 must be installed within 10 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 in) bead of Motorcraft(R) High Performance Engine RTV Silicone on the inside edge of the engine front cover to the engine front cover sealing surfaces including the 2 engine front cover bolt bosses.
- Apply a 5.5 mm (0.21 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
110. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 and tighten sequence shown in 3 stages:
- Stage 1: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 in sequence to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19 and 20 in sequence to 20 Nm (177 lb-in) then an additional 45 degrees.
- Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees.
111. Install the remaining 12 engine front cover bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 16 and 22. Tighten all of the engine front cover bolts in the sequence shown in 3 stages:
- Stage 1: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14 and 16 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14 and 16 to 20 Nm (177 lb-in) then an additional 45 degrees.
- Stage 3: Tighten bolt 22 to 10 Nm (89 lb-in) then an additional 45 degrees.
112. Using a new gasket, install the oil filter adapter and the 5 bolts and tighten in sequence shown.
- Tighten to 10 Nm (89 lb-in) and then an additional 45 degrees.
113. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
If equipped, install the new oil cooler and the mounting bolt.
- Tighten to 58 Nm (43 lb-ft).
114. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
115. Install the 2 RH Camshaft Position (CMP) sensors and the bolts.
- Tighten to 10 Nm (89 lb-in).
116. Install the 2 LH CMP sensors and the bolts.
- Tighten to 10 Nm (89 lb-in).
117. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
118. NOTICE: 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 19 Nm (168 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
119. Install the RH exhaust manifold heat shield and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
120. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
121. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
122. NOTICE: Failure to use the correct Motorcraft(R) 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. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
123. Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
124. Ensure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
125. NOTICE: Only use hand tools when installing the spark plugs, or damage may occur to the cylinder head or spark plug.
Install the 3 RH spark plugs.
- Tighten to 15 Nm (133 lb-in).
126. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
- To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
127. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).
128. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).
129. NOTICE: 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 19 Nm (168 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
130. Install the LH exhaust manifold heat shield and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
131. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
132. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
133. NOTICE: Failure to use the correct Motorcraft(R) 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. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
134. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
135. Ensure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil