Part 2

Engine














Engine - External Components










Engine - Front and Upper Components










Engine - Lower Block Components









NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and 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.

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.

36. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the oil pan-to-engine block mating surface.






37. Position the oil pan onto the engine and install the 13 bolts finger-tight.





38. Using a straight edge, align the front surface of the oil pan flush with the front surface of the engine block.





39. Tighten in the sequence shown to 20 Nm (177 lb-in).





40. Install the 2 cylinder head alignment dowels.





41. Install a new cylinder head gasket.





42. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in 5 stages.

- Stage 1: Tighten to 7 Nm (62 lb-in).

- Stage 2: Tighten to 15 Nm (133 lb-in).

- Stage 3: Tighten to 55 Nm (41 lb-ft).

- Stage 4: Tighten 90 degrees.

- Stage 5: Tighten an additional 90 degrees.






43. NOTE: Lubricate the valve tappets with clean engine oil prior to installing.
Install the 16 valve tappets in their original positions.






44. NOTE: The exhaust camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.

NOTE: Do not allow Gasket Maker to enter the camshaft bearing journal. If Gasket Maker is applied to the camshaft bearing journal, the journal and sealing area must be cleaned with Motorcraft(R) Metal Surface Prep.
Apply 1 mm (0.039 in) beads of Gasket Maker to the exhaust rear camshaft bearing cap as shown.






45. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.

NOTICE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.

NOTICE: Wipe off any excess sealer from the fuel injection pump housing sealing surface of the cylinder head and rear camshaft cap.

NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil.

Install the camshafts and bearing caps in their original location and orientation. Tighten the camshaft bearing caps 2 turns at a time in the sequence shown in 2 stages:
- Stage 1: Tighten to 7 Nm (62 lb-in).

- Stage 2: Tighten to 16 Nm (142 lb-in).






46. NOTE: Lubricate the camshaft journals and the front camshaft bearing cap with clean engine oil.
Install the front camshaft bearing cap and the 3 bolts. Tighten in the sequence shown in 2 stages:

- Stage 1: Tighten to 7 Nm (62 lb-in).

- Stage 2: Tighten to 16 Nm (142 lb-in).






47. Install the 2 VCT (Variable Camshaft Timing) solenoids and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






48. NOTICE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install the Camshaft Alignment Tool into the rear of both of the camshaft slots as shown.
- Tighten the retainer.






49. NOTE: Do not reuse the camshaft phaser and sprocket washers. New washers must be installed.
Install 2 new washers.






50. NOTE: Do not tighten the camshaft phaser and sprocket bolts at this time.
Install the intake and exhaust camshaft phaser and sprockets.

- Install the 2 bolts finger-tight.






51. Install the timing chain onto the 2 camshaft phaser and sprockets and the crankshaft sprocket.
- Install the timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

- Install the timing chain arm.






NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

52. NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.






53. Using a small pick, push back and hold the ratchet mechanism.





54. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





55. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.





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

- Remove the paper clip to release the piston.






57. NOTICE: Do not rely on the Camshaft Alignment Tool to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, tighten the exhaust camshaft phaser and sprocket bolt.
- Tighten to 72 Nm (53 lb-ft).






58. NOTICE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, tighten the intake camshaft phaser and sprocket bolt.
- Tighten to 72 Nm (53 lb-ft).






59. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the sealing surface of the front cover.

- Apply a 2 mm (0.078 in) bead of Silicone Gasket and Sealant to the 5 center sealing surfaces of the front cover.






60. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
Apply beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas.






61. Install the engine front cover, the 20 bolts and 2 stud bolts.
- Tighten in the sequence shown as follows:
- Tighten 1 through 19 to 10 Nm (89 lb-in).

- Tighten 20 through 22 to 48 Nm (35 lb-ft).







62. Install the CKP (Crankshaft Position) sensor and the 2 bolts.
- Align the CKP (Crankshaft Position) sensor so the 2 bolts are located in the middle of the adjustment slots.
- Tighten to 7 Nm (62 lb-in).







63. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.
Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.






64. Install a new diamond washer.





65. NOTE: Apply clean engine oil on the seal contact area before installing.
Position the crankshaft pulley onto the crankshaft and align the TDC (Top Dead Center) marked tooth on the crankshaft pulley (located on the 20th tooth counterclockwise from the missing tooth) with the center line of the CKP (Crankshaft Position) sensor.






66. Install the Crankshaft Sensor Alignment Tool onto the TDC (Top Dead Center) marked tooth on the crankshaft pulley.
- Install a new crankshaft pulley bolt and washer and tighten to 20 Nm (177 lb-in).

- Remove the Crankshaft Sensor Alignment Tool.






67. NOTICE: The crankshaft must remain in the TDC (Top Dead Center) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be installed using hand tools only.

Use the Strap Wrench to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).

- Stage 2: Tighten an additional 90 degrees (one-fourth turn).






68. Remove the Crankshaft TDC (Top Dead Center) Timing Peg.





69. Remove the Camshaft Alignment Tool.





70. NOTE: Only turn the engine in the normal direction of rotation.
Turn the crankshaft clockwise one and three-fourths turns.