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.

All vehicles

109. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.

Install the new oil cooler and the oil cooler insert bolt.

Tighten to 58 Nm (43 lb-ft)





110. Install the Crankshaft Position (CKP) sensor and install the bolt.

Tighten to 10 Nm (89 lb-in).





111. NOTE: Lubricate the 2 CMP sensor O-ring seals with clean engine oil.

Install the 2 RH Camshaft Position (CMP) sensors and the bolts. Install the new the Cylinder Head Temperature (CHT) sensor.

Tighten to 10 Nm (89 lb-in).





112. NOTE: Lubricate the 2 CMP sensor O-ring seals with clean engine oil.

Install the 2 LH CMP sensors and the bolts.

Tighten to 10 Nm (89 lb-in).





113. Install the 8 new RH exhaust manifold studs.

Tighten to 12 Nm (106 lb-in).





114. 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 the 8 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).





115. 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.





116. 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).





117. 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.





118. 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).





119. 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.





120. Install the engine appearance cover bracket and the 2 nuts.

Tighten to 7 Nm (62 lb-in)





121. 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).

122. 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.





123. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts.

Tighten to 7 Nm (62 lb-in).





124. Install the 8 new LH exhaust manifold studs.

Tighten to 12 Nm (106 lb-in).





125. 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 8 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).





126. 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.





127. 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).





128. 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.





129. Using a new gasket, install the LH valve cover and tighten the 11 stud bolts in the sequence shown.

Tighten to 10 Nm (89 lb-in).





130 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.





131 NOTICE: Only use hand tools when installing the spark plugs, or damage may occur to the cylinder head or spark plug.

Install the 3 LH spark plugs.

Tighten to 15 Nm (133 lb-in).

132 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




133 Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts.

Tighten to 7 Nm (62 lb-in).





134. Using new gaskets, install the fuel injection pump mounting plate and bolt.

Tighten finger-tight.





135. NOTICE: Do not attempt to cut the lower Teflon(R) seal without pulling it away from the fuel injector or damage to the fuel injector may occur.

NOTE: Be very careful when removing the lower Teflon(R) seals, not to scratch, nick or gouge the fuel injectors.

Pull the Teflon(R) seal away from the fuel injector with narrow tip pliers.





136. Carefully cut and discard the lower fuel injector Teflon(R) seals.





137. Place the Teflon(R) Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.





138. NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.

Install the new lower Teflon(R) seals on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tip.





139. NOTICE: Once the Teflon(R) seal is installed on the Arbor, it should immediately be installed onto the fuel injector to avoid excessive expansion of the seal.

Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon(R) seals off of the Arbor and into the groove on the fuel injector.





140. NOTE: Make sure the Teflon(R) seal is fully seated in the groove on the fuel injector before sizing the seal.

Slide the Teflon(R) Seal Sizer off the end of the fuel injector to size the seal.





141. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-rings.

NOTE: Apply clean engine oil to the 6 new upper fuel injector O-ring seals.

NOTE: Inspect the fuel injector support disk and replace if necessary.

Install the 6 new upper fuel injector O-ring seals.





142. Install the 6 new fuel injector clips.





143. NOTE: RH shown, LH similar.

NOTE: The anti rotation device on the fuel injector has to slip into the groove of the fuel rail cup.

Install the 6 fuel injectors into the fuel rails and connect the fuel injector electrical connector.





144. NOTICE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.

NOTE: Tighten the bolts using a method that draws the fuel rail evenly to the cylinder head, preventing a rocking motion.

Install the RH fuel rail assembly and the 6 new bolts. Tighten in 3 stages in the sequence shown.

Stage 1: Push down on the fuel rail face above the fuel injectors.

Stage 2: Tighten to 10 Nm (89 lb-in).

Stage 3: Tighten an additional 45 degrees.





145. NOTICE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.

NOTE: Tighten the bolts using a method that draws the fuel rail evenly to the cylinder head, preventing a rocking motion.

Install the LH fuel rail assembly and the 6 new bolts. Tighten in 3 stages in the sequence shown.

Stage 1: Push down on the fuel rail face above the fuel injectors.

Stage 2: Tighten to 10 Nm (89 lb-in).

Stage 3: Tighten an additional 45 degrees.





146 NOTE: Apply clean engine oil to the threads of the 2 high-pressure fuel tube flare nuts.

Position the new high-pressure fuel tube and hand start the flare nuts in 2 stages.

Stage 1: Hand tighten the high-pressure fuel tube-to-RH fuel rail flare nut.

Stage 2: Hand tighten the high-pressure fuel tube-to-LH fuel rail flare nut.





147. Loosely install the bolt for the high-pressure fuel tube.





148. Connect the high-pressure fuel tube to the fuel rails. Tighten in 6 stages.

Stage 1: Tighten the high-pressure fuel tube-to-RH fuel rail flare nut to 15 Nm (133 lb-in).

Stage 2: Tighten an additional 30 degrees.

Stage 3: Tighten to 32 Nm (24 lb-ft).

Stage 4: Tighten the high-pressure fuel tube-to-LH fuel rail flare nut to 15 Nm (133 lb-in).

Stage 5: Tighten an additional 30 degrees.

Stage 6: Tighten to 32 Nm (24 lb-ft).





149. Tighten the bolt for the high-pressure fuel tube.

Tighten the bolt to 10 Nm (89 lb-in) plus an additional 45 degrees.





150. Using new gaskets, install the coolant crossover manifold assembly and the 3 bolts.

Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.





151. NOTE: Lubricate the O-ring seal with clean engine coolant.

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





152. NOTE: Lubricate the O-ring seal with clean engine coolant.

Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7 bolts and tighten in 2 stages in the sequence shown.

Stage 1: Tighten to 10 Nm (89 lb-in).

Stage 2: Tighten an additional 45 degrees.





153. Install the coolant pump pulley and the 4 bolts.

Tighten to 24 Nm (18 lb-ft).





154. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.

Install the thermostat housing and the 4 bolts and tighten in 2 stages in the sequence shown.

Stage 1: Tighten to 8 Nm (71 lb-in).

Stage 2: Tighten an additional 45 degrees.





155. NOTE: Apply thread sealant with PTFE to the threads prior to installing the cylinder block drain plug.

Install the RH cylinder block drain plug.

Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.





156. NOTE: Apply thread sealant with PTFE to the threads prior to installing the cylinder block drain plug.

Install the LH cylinder block drain plug.

Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.





157. Install the accessory drive belt tensioner and the 2 bolts.

Tighten to 25 Nm (18 lb-ft).





158. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.





159. Lubricate the crankshaft front seal inner lip with clean engine oil.

160. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.





161. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.

Stage 1: Tighten to 120 Nm (89 lb-ft).

Stage 2: Loosen one full turn.

Stage 3: Tighten to 50 Nm (37 lb-ft).

Stage 4: Tighten an additional 90 degrees.





162. Position the engine wire harness on the engine. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

163. Connect the 3 RH ignition coil-on-plug electrical connectors.





164. Connect the 2 RH VCT solenoid electrical connectors.