Part 3

Engine


















Engine Upper










Engine Front










Engine Lower (View 1)










Lower Engine (View 2)










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head









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: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.

NOTE: The Differential Bearing Cone Installer is used to install the Variable Camshaft Timing (VCT) solenoid seals.


81. Install the primary timing chain tensioner arm.





82. 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.






83. 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.






84. As a post-check, verify correct alignment of all timing marks.
- There is 48 links in between the RH intake VCT (Variable Camshaft Timing) assembly colored link (1) and the LH intake VCT (Variable Camshaft Timing) assembly colored link (2).

- There is 35 links in between LH intake VCT (Variable Camshaft Timing) assembly colored link (2) and the 2 crankshaft sprocket links (3).






85. 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 (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Install the LH intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.






86. 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 (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Install the RH intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.






87. Remove the RH Camshaft Holding Tool.





88. 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.






89. Remove the LH Camshaft Holding Tool.





90. 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.






91. NOTICE: Only use a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.

Clean the engine front cover using a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.


92. NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTICE: Do not use wire brushes, power abrasive discs or 3M(TM) Roloc(R) Bristle Disk (2-in white part number 07528) to clean the sealing surfaces of engine block, cylinder heads, and oil pan. These tools can cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
1. Remove any large deposits of silicone or gasket material.

2. Apply silicone gasket remover and allow to set for several minutes.

3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.


93. Install the Alignment Pins.





94. 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.

NOTE: The engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover 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 to the engine front cover sealing surfaces including the 4 inner 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.






95. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22.

- Tighten in sequence to 3 Nm (27 lb-in).






96. Remove the Alignment Pins.





97. NOTE: Do not tighten the bolt at this time.
Install the M6 engine front cover bolt.






98. NOTE: Do not tighten the bolts at this time.
Install the 3 M10 engine front cover bolts.






99. 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 this instruction may cause oil leakage.

Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 7 stages:
- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).

- Stage 2: Tighten bolts 23, 24 and 25 to 15 Nm (133 lb-in).

- Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in).

- Stage 4: Loosen bolt 26 one full turn.

- Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees.

- Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees.

- Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.






100. NOTE: Installation of new seals is only required if damaged seals were removed.

NOTE: RH shown, LH similar.
Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.






101. NOTE: Installation of new seals is only required if damaged seals were removed.

NOTE: RH shown, LH similar.
Using the Differential Bearing Cone Installer and Handle, install new VCT (Variable Camshaft Timing) solenoid seal(s).






102. 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.






103. Using a new gasket, install the RH valve cover and tighten the 4 bolts and 7 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






104. Make sure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the VCT (Variable Camshaft Timing) oil control solenoid electrical connector or the VCT (Variable Camshaft Timing) seal may leak oil.





105. Install the 3 RH -coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).






106. 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.

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.






107. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






108. Make sure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the VCT (Variable Camshaft Timing) oil control solenoid electrical connector or the VCT (Variable Camshaft Timing) seal may leak oil.





109. Install the 3 LH -coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in.






110. Using a new gasket, install the oil filter adapter and the 3 bolts.
- Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.






111. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.
Install the EOP (Engine Oil Pressure) switch.

- Tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.






112. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).






113. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.





114. NOTE: Apply clean engine coolant to the O-ring seal prior to installation.
Using a new O-ring seal, install the coolant inlet tube and thermostat assembly.






115. 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 new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






116. Install the 2 thermostat housing-to-lower intake manifold bolts.
- Tighten to 10 Nm (89 lb-in).






117. NOTE: Lubricate the 2 Camshaft Position (CMP) sensor O-ring seals with clean engine oil.
Install the 2 RH CMP (Camshaft Position) sensors and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).






118. NOTE: Lubricate the 2 CMP (Camshaft Position) sensor O-ring seals with clean engine oil.
Install the 2 LH CMP (Camshaft Position) sensors and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).






119. Install the cover and the pin-type retainer.





120. If equipped, install the block heater wiring harness onto the engine.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.

- Tighten the block heater to 40 Nm (30 lb-ft).