Steps 64 - 126

NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure.

64. Note: The LH cylinder head is shown, the RH is similar.

Install the eight 12mm bolts and tighten to 35 Nm (26 ft. lbs.) in the sequence shown.

65. Note: The LH cylinder head is shown, the RH is similar.

Install the two 8 mm bolts.

66. Note: LH cylinder head is shown, RH is similar.

Tighten the eight 12 mm bolts in the sequence shown in two stages.
- Stage 1: Rotate 90 degrees.
- Stage 2: Rotate an additional 90 degrees.

67. Using the special tool, install the crankshaft pulley.

68. CAUTION: A new bolt must be used each time it is removed.

Tighten the bolt in two stages.
- Stage 1: Tighten 45 Nm (33 ft. lbs.).
- Stage 2: Rotate an additional 90 degrees.

69. Note: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install the RH rear camshaft bolt.

70. Install the bolt.

71. Note: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install the LH front camshaft bolt.

72. Install the bolt.
73. Turn the crankshaft one revolution clockwise.

74. Note: The special tool must be installed on the damper and should contact the engine block, this positions the engine at top dead center (TDC).

Install the special tool.

75. Note: Camshaft timing slots are off-center.

Note: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the front of the RH cylinder head.

76. Note: Leave the top two special tool clamp bolts loose.

Install the special tools on the rear of the RH cylinder head.

77. Install the special tool.

78. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

Tighten the bolts.
1 Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt.

79. Remove the special tool and install the RH camshaft tensioner.
80. Remove the special tools from the RH cylinder head.

81. Note: Do not tighten the special tool top two clamp bolts. Camshaft sprocket must rotate freely.

Install the special tools on the front of the LH cylinder head.

82. Note: Camshaft timing slots are off-center.

Note: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the rear of the LH cylinder head.

83. Install the special tool.

84. Tighten the bolts.
1 Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt.

85. Remove the special tool and install the LH camshaft tensioner.
86. Remove the special tools from the LH cylinder head.

87. Remove the special tool.

88. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installing.

Using the special tool, install the roller followers in their original position.

89. Install the gasket and the LH exhaust manifold.

90. Install the gasket and the RH exhaust manifold.

91. Note: Prior to installation, use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to clean mating surfaces.

Install the knock sensor.

92. Install the oil level indicator tube.

93. Note: If the oil level indicator tube is not installed flush with the cylinder block, false readings of the oil level may occur.

Make sure the oil level indicator tube is flush with the cylinder block.

94. install the crankcase vent separator.

95. Install the thermostat housing.
- Inspect and install a new gasket if necessary.

96. Connect the water bypass hose.

97. Install the vapor management valve (VMV) hose bracket.

98. Install the fuel injectors.
- Lubricate the fuel injector O-ring seals with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

99. Install the gasket and the RH valve cover.

100. Install the gasket and the LH valve cover.

101. Install the fuel injection supply manifold.

102. Install the lower fuel line bracket.

103. Connect the EGR valve to exhaust manifold tube to the exhaust manifold.

104. Connect the EGR valve to exhaust manifold tube to the EGR valve.

105. Install the fuel charging wiring.

106. Note: The LH side is shown, the RH side is similar.

Connect the six fuel injector electrical connectors.

107. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.

108. Install the lower intake manifold.

109. Connect the LH (VMV) hose.

110. Connect the RH VMV hose.

111. Install the upper intake manifold.
- Inspect and install a new gasket if necessary.

112. Connect the crankcase ventilation hose.

113. Connect the RH upper intake manifold vacuum hose.

114. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.

Note: Apply Silicone Brake Caliper and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug boots.

Install the spark plug wires to the spark plugs.