Part 3
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.
71. Install the Crankshaft TDC (Top Dead Center) Timing Peg.
72. NOTE: The engine front cover is shown removed in graphic for clarity.
Rotate the crankshaft slowly clockwise until the crankshaft contacts the Crankshaft TDC (Top Dead Center) Timing Peg.
- The TDC (Top Dead Center) marked tooth on the crankshaft pulley will align with the center line of the CKP (Crankshaft Position) sensor.
73. Install the Camshaft Alignment Tool to check the position of the camshaft.
- If it is not possible to install the Camshaft Alignment Tool, the engine valve timing must be corrected.
74. Install the Crankshaft Sensor Alignment Tool.
- If the Crankshaft Sensor Alignment Tool does not align with the TDC (Top Dead Center) marked tooth on the crankshaft pulley, loosen the 2 CKP (Crankshaft Position) sensor bolts and adjust the sensor until the tool is installed.
- Tighten the 2 CKP (Crankshaft Position) sensor bolts to 7 Nm (62 lb-in).
- Remove the Crankshaft Sensor Alignment Tool.
75. Remove the Camshaft Alignment Tool.
76. Remove the Crankshaft TDC (Top Dead Center) Timing Peg.
77. Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).
78. Using a wrench on the flats of the intake camshaft to prevent cam rotation, install the brake vacuum pump adapter.
- Tighten to 63 Nm (46 lb-ft).
79. NOTE: The intake 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.
Apply 1 mm (0.039 in) beads of Gasket Maker to the intake rear camshaft bearing cap mating surface as shown.
80. NOTICE: Wipe off any excess sealer from the vacuum pump sealing surface of the cylinder head and camshaft cap.
Install the rear intake camshaft cap and the 2 bolts. Tighten the bolts in 2 stages:
- Stage 1: Tighten the bolts to 7 Nm (62 lb-in).
- Stage 2: Tighten the bolts to 16 Nm (142 lb-in).
81. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT (Variable Camshaft Timing) solenoid seals.
82. Apply a 5.5 mm (0.216 in) drop of silicone gasket and sealant to the 6 locations shown.
83. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.
Using a new gasket install the valve cover.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
84. Install the oil level indicator.
- Install the 4 coil-on-plugs and the 4 bolts.
- Tighten to 8 Nm (71 lb-in).
- Install the CAC (Charge Air Cooler) intermediate tube mounting bracket, nut and bolt.
- Tighten to 8 Nm (71 lb-in).
85. Slide the vacuum hose assembly onto the valve cover tab and attach the 2 retainers.
86. Position the wiring harness onto the engine and attach the 7 retainers.
- Connect the 9 wiring harness electrical connectors.
87. Using the crankshaft pulley bolt, rotate the engine clockwise until the fuel injection cam lobe is at zero lift.
88. Inspect the fuel injection pump housing gasket and replace as necessary.
89. Install the fuel injection pump housing, the 4 bolts and tighten in 2 stages.
- Stage 1: Tighten to 15 Nm (177 lb-in).
- Tighten an additional 60 degrees.
90. NOTE: Apply clean engine oil to the fuel injection pump tappet and to the fuel injection pump housing bore.
Slide the fuel injection pump tappet into the fuel injection pump housing.
91. NOTE: Make sure that a new fuel injection pump O-ring seal is installed.
Install a new fuel injection O-ring seal.
- Lubricate the O-ring seal with clean engine oil.
92. Install the fuel injection pump and loosely install 2 fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated. Tighten the 2 fuel injection pump bolts in the following 2 stages.
- Stage 1: Tighten each bolt to 5 Nm (44 lb-in).
- Stage 2: Tighten each bolt an additional 55 degrees.
93. Install the fuel injection pump bracket and the 2 bolts.
- Tighten to 17 Nm (150 lb-in).
94. Inspect and, if necessary, install a new brake vacuum pump gasket.
95. Install the brake vacuum pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
96. Inspect and, if necessary, install a new thermostat housing gasket.
97. Install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
98. NOTICE: Do not use compressed air or the Fuel Injector Brush to clean the tip of the fuel injectors. Failure to follow this instruction may result in damage to the fuel injectors.
NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
NOTE: Using the Fuel Injector Brush, clean the fuel injector orifices.
99. NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.
Install new lower Teflon(R) fuel injector seals.
1. Place the Teflon(R) Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
2. Install the new lower Teflon(R) seal on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tip.
- 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 injectors.
100. NOTICE: Install the fuel injectors into the cylinder head within 15 minutes due to Teflon(R) seal expansion.
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 down over the Teflon(R) seal.
101. 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-ring seals.
Assemble the fuel injectors.
1. Install the upper fuel injector O-ring seal support ring
2. Install a new upper fuel injector O-ring seal.
- Lubricate the O-ring seal with clean engine oil.
3. Install a new fuel injector retainer clip
102. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
Install the fuel injectors into the fuel rail.
103. Position the fuel rail and fuel injectors into the cylinder head and push down on the fuel rail face above the injectors.
- Install 5 new bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 26 degrees.
104. Install a new high pressure fuel tube and hand tighten the 2 flare nuts.
105. Loosely install the 2 high pressure fuel tube bracket bolts.
