Engine Mechanical - 3.7L: Other Ford Mustang V рестайлинг 2

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

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Exhaust Emission Control System

Operation and required maintenance of the exhaust emission control devices used on this engine is covered in the ENGINE CONTROLS - INTRODUCTION (EXCEPT DIESEL & HYBRID) (SECTION 0) .

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated fuel injectors

1. are mounted between the fuel rail and the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.

Valve Train

The valve train uses Direct Acting Mechanical Buckets (DAMB). The camshaft lobes are positioned directly above mechanical buckets which are positioned on top of the valves.

Twin Independent Variable Camshaft Timing (VCT) System

The twin independent VCT system allows variable control of intake valve closing which optimizes combustion at full load providing improved power and low speed torque (broadening the torque curve) which enables variable valve overlap which provides better fuel economy and emissions and provides optimized cold start operation with improved exhaust emissions.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake manifold.

Oil Pump

The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range.

The heart of the system is a positive displacement internal gear oil pump.

Generically, this design is known as a gerotor pump, which operates as follows

1. The oil pump is mounted on the front face of the cylinder block.
2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
4. Oil pump displacement has been selected to provide adequate volume to ensure correct oil pressure both at hot idle and maximum speed.
5. The relief valve calibration protects the system from excessive pressure during high-viscosity conditions.
6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

Dual Mass Flywheel

Note. The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).

A dual-mass flywheel is essentially two flywheels in one that provides spring cushioning to dampen torsional crankshaft vibrations and shock loading when the clutch is engaged. The two-piece assembly has a front "primary" mass and a rear "secondary" mass. The primary mass bolts to the crankshaft like an ordinary solid flywheel, and includes the ring gear for the starter. The clutch is bolted to the secondary mass, which is separate from the primary mass, but attached to it with a series of coil springs mounted sideways between the two. The springs allow just enough movement between the masses to transmit less engine vibration to the driveline, reduce some of the jarring and stress on the transmission and the remainder of the drivetrain when the clutch is engaged. The cushioning effect also reduces shock loading on the transmission for longer gear life and less noise.

Cooling System

The engine cooling system includes the following

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1. Radiator
2. Coolant pump
3. Electric fan assembly(s)
4. Degas bottle (aids in maintaining the correct volume of engine coolant)
5. Coolant thermostat
6. Coolant hoses

The channel cover plate is located under the engine front cover mounted to the block. It contains a timing chain idler and press and place gaskets separating engine coolant and engine oil. If oil or coolant is leaking from the weep hole, then a gasket has failed and must be replaced. A weep hole is provided on the front left side of the engine behind the generator. This weep hole create a reservoir for normal coolant seepage and evaporation. Every channel cover plate will have some leakage past the dynamic mechanical seal. Dampness and crusting around the weep hole is acceptable and an expected result of normal engine operation. Coolant spray or leakage amounts great enough to puddle should be addressed.

For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION . For driveability concerns, refer to the ENGINE CONTROLS - INTRODUCTION (EXCEPT DIESEL & HYBRID) (SECTION 0) .

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1. Remove the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-574170-S04295623372013082300000) and «VALVE COVER - RH»(ref-574170-S32184116462013082300000) .
2. NOTE: Engine must be at room temperature before measuring. The valve clearance must be measured with the camshaft at base circle. The engine will have to be rotated with the crankshaft pulley bolt to bring each valve to base circle. Use a feeler gauge to measure the clearance of each valve and record its location. A midrange clearance is the most desirable: Intake: 0.15-0.25 mm (0.006-0.01 in) Exhaust: 0.360-0.460 mm (0.0142-0.0181 in)
3. NOTE: The number on the valve tappet reflects the thickness of the valve tappet. For example, a tappet with the number 3.310 has the thickness of 3.31 mm (0.13 in). If any of the valve clearances are out of specification, select new tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location.
4. If required, install the new selected valve tappets in the marked locations. For additional information, refer to «VALVE TAPPETS»(ref-574170-S30972509412013082300000) .

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Valve Cover - LH

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Installer, Spark Plug Tube Seal 303-1247/2 Remover, Spark Plug Tube Seal 303-1247/1

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MATERIAL SPECIFICATIONS

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Valve Cover - RH

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Installer, Spark Plug Tube Seal 303-1247/2 Remover, Spark Plug Tube Seal 303-1247/1

MATERIAL SPECIFICATIONS

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Crankshaft Pulley

SPECIAL TOOLS 3 Jaw Puller 303-D121 or equivalent Installer, Front Cover Oil Seal 303-335 Replacer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-574118) .
2. Remove the accessory drive belt and the A/C belt. For additional information, refer to «ACCESSORY DRIVE»(ref-574129) .
3. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
4. Using the 3 Jaw Puller, remove the crankshaft pulley. Inspect the crankshaft pulley sealing surface for nicks or scratches that may effect the crankshaft front seal lip, replace the crankshaft pulley if necessary.

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1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. 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.
3. 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.
4. Install the accessory drive belt and the A/C belt. For additional information, refer to «ACCESSORY DRIVE»(ref-574129) .
5. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

Crankshaft Front Seal

SPECIAL TOOLS Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Crankshaft Seal 303-1251 Remover, Oil Seal 303-409 (T92C-6700CH)

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MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-574118) .
2. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-574170-S00425338002013082300000) .
3. Using the Oil Seal Remover, remove and discard the crankshaft front seal. Clean all sealing surfaces with metal surface prep.

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1. 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.
2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-574170-S00425338002013082300000) .

Engine Front Cover

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Spindle Bearing 205-149 (T80T-4000-R) Installer, Spindle Bearing 205-150 (T80T-4000-S)

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MATERIAL SPECIFICATIONS

Note. Engine Front Cover (View 1 of 2)

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Note. Engine Front Cover (View 2 of 2)

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Timing Drive Components

SPECIAL TOOLS Hold Down, Secondary Chain 303-1530 Tool, Camshaft Holding 303-1248

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Front Cover Radial Seal

SPECIAL TOOLS Remover/Installer, Water Tube Seal 303-1528

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Valve Train Components - Exploded View

Note. Valve Train Components (View 1 of 2)

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Note. Valve Train Components (View 2 of 2)

Note. LH shown in illustration, RH similar.

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1. Refer to the procedures and/or exploded views for any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of removal.

Camshaft - LH

SPECIAL TOOLS Hold Down, Secondary Chain 303-1530 Tool, Camshaft Holding 303-1248

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MATERIAL SPECIFICATIONS

Valve Tappets

MATERIAL SPECIFICATIONS

Valve Spring, Retainer and Seal

SPECIAL TOOLS Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

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MATERIAL SPECIFICATIONS

Cylinder Head - LH

MATERIAL SPECIFICATIONS

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Cylinder Head - RH

MATERIAL SPECIFICATIONS

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Exhaust Manifold - LH

MATERIAL SPECIFICATIONS

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Exhaust Manifold - RH

MATERIAL SPECIFICATIONS

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Oil Pan

SPECIAL TOOLS Eye, Engine Lift 303-1245 Lift Eye, RH Front 303-1529 Support Bar, Engine 303-F072

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MATERIAL SPECIFICATIONS

SPECIAL TOOLS Eye, Engine Lift 303-1245 Lift Eye, RH Front 303-1529 Support Bar, Engine 303-F072 Tool, Camshaft Holding 303-1248

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Engine Oil Pressure (EOP) Switch

MATERIAL SPECIFICATIONS

Note. The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).

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1. Refer to the procedures and/or exploded views for any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of removal.

Flexplate

SPECIAL TOOLS Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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Flywheel

SPECIAL TOOLS Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Crankshaft Rear Seal

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Rear Main Seal 303-1250 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B)

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MATERIAL SPECIFICATIONS

Crankshaft Rear Seal with Retainer Plate

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Rear Main Seal 303-1250 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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MATERIAL SPECIFICATIONS

Engine Support Insulators

SPECIAL TOOLS Eye, Engine Lift 303-1245 Lift Eye, RH Front 303-1529 Support Bar, Engine 303-F072

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Cylinder Head

SPECIAL TOOLS Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

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MATERIAL SPECIFICATIONS

Note. RH cylinder head shown in illustration, LH cylinder head similar.

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Piston

MATERIAL SPECIFICATIONS

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1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin. Discard the 2 piston pin retainer clips.
3. NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block. NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod for reassembly. Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-574124) .

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1. Align the piston-to-connecting rod orientation marks and position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the new piston pin retaining clips in the piston. The piston pin retaining clip gap orientation must be toward the top or dome of piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring face pointing up toward the top of the piston. Install the piston rings onto the piston as shown in illustration. Center line of the piston parallel to the wrist pin bore Upper compression ring gap location Upper oil control segment ring gap location Lower oil control segment ring gap location Expander ring and lower compression ring gap location

SPECIAL TOOLS Compressor, Piston Ring 303-D032 (D81L-6002-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Eye, Engine Lift 303-1245 Lift Eye, RH Front 303-1529 Handle 205-153 (T80T-4000-W) Hold Down, Secondary Chain 303-1530 Installer, Differential Bearing Cone 205-142 (T80T-4000-J) Installer, Spindle Bearing 205-149 (T80T-4000-R) 2, 200# Floor Crane, Fold Away 300-OTC1819E Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Front Crankshaft Seal 303-1251 Installer, Rear Main Seal 303-1250 Installer, VCT Spark Plug Tube Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A) Tool, Camshaft Holding 303-1248

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MATERIAL SPECIFICATIONS

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Note. 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. The engine is equipped with a cast aluminum (early build) or stamped steel (late build) crankshaft rear seal retainer plate. If the engine is equipped with a stamped steel plate, the seal and plate must be removed as an assembly and discarded.

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. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

All vehicles

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1. NOTE: This procedure is for selecting bearings using a new crankshaft. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block face. The first letter after the first asterisk makes up the code for main No. 1 and the next letter for main No. 2. The first letter after the second asterisk makes up the code for main No. 3 and the last letter for main No. 4.
2. NOTE: This chart is for selecting main bearings 1 and 4 only, the remaining bearings will be selected using a different chart in the next step. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing. Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
3. NOTE: This chart is for selecting main bearings 2 and 3 only. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3. Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is "1". Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
4. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Using the original connecting rod cap bolts, install the connecting rod caps and bolts. Tighten the bolts in 3 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Measure the connecting rod large end bore in 2 directions. Remove the bolts and the rod cap. Discard the connecting rod cap bolts.
6. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
7. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
8. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
9. NOTE: Do not install the upper thrust bearings until the crankshaft is installed. NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil. Install the crankshaft onto the upper main bearings.
10. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.
11. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.
12. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.
13. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
14. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer. Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.
15. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
16. Loosen the No. 4 main bearing cap bolts.
17. NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers. Tighten the main bearing bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 33 Nm (24 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 135 degrees.
18. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 24 Nm (18 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 180 degrees.
19. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
20. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Prepare the connecting rod and cap. Insert the new bolts in the rod cap. Insert the upper and lower rod bearings into the rod and cap.
21. Before installing the pistons into the cylinder block, verify proper ring gap location. Center line of the piston parallel to the wrist pin bore Upper compression ring gap location Upper oil control segment ring gap location Lower oil control segment ring gap location Expander ring and lower compression ring gap location
22. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown in illustration. NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil. NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to «PISTON»(ref-574170-S13485163772013082300000) . NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block. NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled. Using the Piston Ring Compressor, install the piston and connecting rod assemblies.
23. Seat the connecting rod on the crankshaft journal.
24. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation. Install the connecting rod cap and bolts. Tighten the bolts in 3 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Tighten an additional 90 degrees.
25. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
26. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in illustration in 2 steps. Stage 1: Tighten fasteners to 20 Nm (177 lb-in). Stage 2: Tighten fasteners an additional 180 degrees.
27. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application. NOTE: Cast aluminum (early build) crankshaft rear seal retainer plate shown in illustration, stamped steel (late build) crankshaft rear seal retainer plate is similar. NOTE: The stamped steel (late build) crankshaft rear seal retainer plate comes with the crankshaft rear seal. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.
28. Install the crankshaft rear seal retainer and the 8 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
29. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
30. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten to 10 Nm (89 lb-in).
31. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan-to-engine block mating surface.
32. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
33. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application. Install the oil pan and bolts 10, 11, 13 and 14 finger tight.
34. Laterally align the oil pan to the block. Make sure the oil pan is flush with the block at these 2 points.
35. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration to 3 Nm (27 lb-in).
36. Install the remaining oil pan bolts and tighten in the sequence shown in illustration. Tighten bolts 1-9 and 11-14 to 20 Nm (177 lb-in), then rotate an additional 45 degrees. Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees. Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.
37. Install the Knock Sensor (KS) and the 2 bolts. Tighten to 20 Nm (177 lb-in).
38. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 45 degrees.
39. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
40. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 45 degrees.
41. Install the M6 bolt. Tighten to 10 Nm (89 lb-in).
42. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
43. NOTE: 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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Using new lower intake manifold gaskets, install the lower intake manifold and the 10 bolts and tighten in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
44. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation. NOTE: LH shown in illustration, RH similar. Install the valve tappets.
45. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage. Position the crankshaft dowel pin in the 9 o'clock position.
46. NOTE: Coat the camshafts with clean engine oil prior to installation. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.
47. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur. Position the 4 camshaft seals gaps as shown in illustration.
48. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration. Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
49. Loosen the 4 camshaft caps bolts.
50. Tighten the 4 camshaft caps bolts in the sequence shown in illustration. Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
51. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur. NOTE: Use a camshaft sprocket bolt to turn the camshafts. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-574170-S07780537652013082300000) .
52. Remove the 3 bolts and the RH valve train oil tube.
53. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown in illustration.
54. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
55. NOTE: Coat the camshafts with clean engine oil prior to installation. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.
56. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur. Position the 4 camshaft seals gaps as shown in illustration.
57. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration. Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
58. Loosen the 4 camshaft caps bolts.
59. Tighten the 4 camshaft caps bolts in the sequence shown in illustration. Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
60. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur. NOTE: Use a camshaft sprocket bolt to turn the camshafts. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-574170-S07780537652013082300000) .
61. Remove the 3 bolts and the LH valve train oil tube.
62. Rotate the LH camshafts to the TDC position as shown in illustration.
63. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
64. Using a new gasket, install the channel cover plate and the 9 bolts. Tighten in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
65. Install the RH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in). Engines with secondary timing chain tensioner removed NOTE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed or damage to the engine may occur.
66. NOTE: Apply clean engine oil to the secondary timing chain tensioner O-ring seals and mega cap bore. NOTE: Do not remove the secondary timing chain tensioner shipping clip, until instructed to do so. Install the RH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.
67. Install the RH secondary timing chain tensioner shoe.
68. Remove and discard the RH secondary timing chain tensioner shipping clip.
69. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
70. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly. Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
71. Install the 2 new RH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
72. Activate the RH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
73. NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid. NOTE: Keep the VCT oil control solenoid clean of dirt and debris. Install the RH exhaust VCT oil control solenoid. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
74. NOTE: Apply clean engine oil to the secondary timing chain tensioner O-ring seals and mega cap bore. NOTE: Do not remove the secondary timing chain tensioner shipping clip, until instructed to do so. Install the LH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.
75. Install the LH secondary timing chain tensioner shoe.
76. Remove and discard the LH secondary timing chain tensioner shipping clip.
77. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
78. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly. Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
79. Install the 2 new LH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
80. Activate the LH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
81. NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid. NOTE: Keep the VCT oil control solenoid clean of dirt and debris. Install the LH exhaust VCT oil control solenoid. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees. Engines with secondary timing chain tensioner not removed
82. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
83. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
84. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly. Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
85. Install the 2 new RH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
86. NOTE: The 2 VCT oil control solenoids are removed for clarity. Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
87. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
88. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
89. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly. Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
90. Install the 2 new LH VCT bolts and tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 25 Nm (18 lb-ft). Stage 4: Tighten an additional 180 degrees.
91. NOTE: The 2 VCT oil control solenoids are removed for clarity. Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down. Make sure the secondary timing chain is centered on the timing chain tensioner guides. All engines
92. Install the upper LH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
93. Rotate the crankshaft clockwise to the TDC position (crankshaft dowel pin at 11 o'clock).
94. Install the crankshaft timing chain sprocket with timing dot mark out.
95. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
96. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
97. Install the primary timing chain tensioner arm.
98. 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.
99. 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.
100. As a post-check, verify correct alignment of all timing marks. There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2). There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
101. NOTE: 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 oil control solenoid, inspect the bore and VCT 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 oil control solenoid. NOTE: Keep the VCT oil control solenoid clean of dirt and debris. Install the LH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
102. NOTE: 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 oil control solenoid, inspect the bore and VCT 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 oil control solenoid. NOTE: Keep the VCT oil control solenoid clean of dirt and debris. Install the RH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
103. Remove the RH Camshaft Holding Tool.
104. 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.
105. Remove the LH Camshaft Holding Tool.
106. 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.
107. NOTE: Use Spindle Bearing Installer 205-149 to install the seal. Using the Spindle Bearing Installer, install the front cover radial seal from the rear side of the front cover.
108. NOTE: Failure to use Motorcraft® 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 1, 2, 7, 8, 16, 17, 18, 19, 20 and 21 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket 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® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 2 engine front cover bolt bosses. Apply a 5.5 mm (0.21 in) bead of Motorcraft® 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.
109. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block. Install the engine front cover and bolts 1, 2, 7, 8, 16, 17, 18, 19, 20 and 21. Tighten in sequence to 3 Nm (27 lb-in).
110. Install the remaining 18 engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in illustration in 4 stages: Stage 1: Tighten bolts 1 through 21 to 10 Nm (89 lb-in). Stage 2: Tighten bolts 1 through 20 to 24 Nm (18 lb-ft). Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees. Stage 4: Tighten bolt 22 to 10 Nm (89 lb-in) then an additional 45 degrees.
111. Using a new gasket, install the oil filter adapter and the 5 bolts and tighten in sequence shown in illustration. Tighten to 10 Nm (89 lb-in) and then an additional 45 degrees.
112. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
113. Install the 2 RH Camshaft Position (CMP) sensors and the bolts. Tighten to 10 Nm (89 lb-in).
114. Install the 2 LH CMP sensors and the bolts. Tighten to 10 Nm (89 lb-in).
115. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
116. NOTE: 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 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 19 Nm (168 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
117. Install the RH exhaust manifold heat shield and the 2 bolts. Tighten to 10 Nm (89 lb-in).
118. 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.
119. 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).
120. NOTE: Failure to use the correct Motorcraft® 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® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
121. Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
122. 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.
123. NOTE: 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).
124. 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.
125. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts. Tighten to 7 Nm (62 lb-in).
126. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
127. NOTE: 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 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 19 Nm (168 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
128. Install the LH exhaust manifold heat shield and the 2 bolts. Tighten to 10 Nm (89 lb-in).
129. 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.
130. 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).
131. NOTE: Failure to use the correct Motorcraft® 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® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
132. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
133. 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.
134. NOTE: 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).
135. 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.
136. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts. Tighten to 7 Nm (62 lb-in).
137. 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 the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
138. Install the coolant pump pulley and the 4 bolts. Tighten to 24 Nm (18 lb-ft).
139. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant. Install the thermostat housing and the 4 bolts and tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 45 degrees.
140. Attach the heater tube retainer to the RH valve cover stud bolt.
141. Install the heater tube bolt. Tighten to 23 Nm (17 lb-ft).
142. Install the RH cylinder block drain plug. Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
143. Install the LH cylinder block drain plug or, if equipped, the block heater. 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).
144. Install the accessory drive belt tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
145. 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.
146. Lubricate the crankshaft front seal inner lip with clean engine oil.
147. 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.
148. 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.
149. Install the generator stud and position the generator and install the nut and bolt. Tighten the stud to 8 Nm (71 lb-in). Tighten the nut and bolt to 48 Nm (35 lb-ft).
150. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
151. Connect the CKP sensor electrical connector.
152. Install the wiring harness grommet.
153. Install the wiring harness retainer stud bolt. Tighten to 10 Nm (89 lb-in).
154. Install the heat shield, the nut and the bolt. Tighten to 10 Nm (89 lb-in).
155. Connect the 2 LH CMP sensors electrical connectors. Attach the wiring harness retainer to the rear of the cylinder head.
156. Connect the KS sensor electrical connector.
157. Connect the 2 LH VCT solenoid electrical connectors.
158. Connect the 3 LH fuel rail electrical connectors.
159. Connect the 3 LH ignition coil-on-plug electrical connectors.
160. Connect the Engine Oil Pressure (EOP) switch electrical connector. Attach the EOP switch wiring harness retainer to the cylinder head.
161. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
162. Connect the 2 RH CMP sensors electrical connectors.
163. Connect the 2 RH VCT solenoid electrical connectors.
164. Connect the 3 RH fuel rail electrical connectors.
165. Connect the CHT sensor wiring harness jumper electrical connector.
166. Connect the 3 RH ignition coil-on-plug electrical connectors.
167. Install the RH fuel rail insulator.
168. NOTE: 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 gaskets, install the upper intake manifold and tighten the 7 bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
169. Install the upper intake manifold support bracket bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
170. Install the LH fuel rail insulator.
171. Attach the wiring harness pin-type retainer to the rear of the upper intake manifold.
172. Connect the PCV tube quick connect couplings to the PCV valve and intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-574171) .
173. Connect the Throttle Body (TB) electrical connector. Attach the TB electrical connector wiring harness pin-type retainer to the TB.
174. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector. Attach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
175. Install the engine oil level indicator.
176. Install the crankcase vent tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-574171) .
177. Install the LH engine lift eye.
178. Install the RH front lift eye.
179. Using the Floor Crane and Spreader Bar, remove the engine from the stand. Cast aluminum (early build) crankshaft rear seal retainer plate
180. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
181. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal. All engines
182. Install the crankshaft sensor ring.
183. NOTE: Flexplate shown in illustration, flywheel similar. Install the spacer plate. Engines with manual transmission
184. NOTE: The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face). Install the flywheel and the 8 bolts and tighten is sequence shown in illustration. Tighten to 80 Nm (59 lb-ft).
185. NOTE: If installing the original pressure plate, align it using the index marks made during removal. NOTE: Always install new pressure plate bolts. Using a suitable clutch aligner, position the clutch disc on the flywheel, install the pressure plate and 6 new pressure plate bolts. Turn the bolts 1-2 turns at a time in a star pattern until the clutch is fully secured. Tighten the pressure plate bolts in 2 stages in a star pattern Stage 1: Tighten to 47 Nm (35 lb-ft). Stage 2: Tighten an additional 60 degrees. Engines with automatic transmission
186. Install the flexplate and the 8 bolts and tighten is sequence shown in illustration. Tighten to 80 Nm (59 lb-ft).

Engine - Automatic Transmission

SPECIAL TOOLS 2, 200# Floor Crane, Fold Away 300-OTC1819E Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

MATERIAL SPECIFICATIONS

Scheme 354

1. NOTE: Prior to installation of the engine, the torque converter pilot hub must be lubricated with multi-purpose grease or damage to the torque converter or the engine crankshaft can occur. Lubricate the torque converter pilot hub with multi-purpose grease.
2. Using the Floor Crane and Spreader Bar, position the engine in the engine compartment.
3. Align the engine to the transmission and install LH bellhousing-to-engine bolt. Tighten the bolt, it will be torqued at a later step.
4. Install the engine-to-bellhousing bolt. Tighten the bolt, it will be torqued at a later step.
5. Install the RH engine mount bracket, bolt and 2 stud bolts (2 shown in illustration). Tighten to 55 Nm (41 lb-ft).
6. Install the LH engine mount bracket and the 3 bolts (2 shown in illustration). Tighten to 55 Nm (41 lb-ft).
7. Install the 4 upper bellhousing-to-engine bolts and stud bolts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
8. Attach the 2 wiring harness retainers (1 shown in illustration) to the upper transmission stud bolts.
9. Install the ground wire and the bolt on the rear of the cylinder head. Tighten to 10 Nm (89 lb-in).
10. Install the oil pan-to-bellhousing bolt. Tighten to 48 Nm (35 lb-ft).
11. Tighten the engine-to-bellhousing bolt. Tighten to 48 Nm (35 lb-ft).
12. Install the 2 LH bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the LH bellhousing-to-engine bolt. Tighten to 48 Nm (35 lb-ft).
14. Tighten LH bellhousing-to-engine bolt. Tighten to 48 Nm (35 lb-ft).
15. Remove the 3 bolts and lower the underbody shield.
16. Position the transmission cooler tubes clamp on the RH engine mount bracket stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
17. Position the wiring harness retainer on the RH rear engine mount bracket stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
18. NOTE: LH shown in illustration, RH similar. Install the new 2 LH and RH catalytic convertor-to-exhaust manifold nuts. Tighten to 45 Nm (35 lb-ft).
19. Install the 4 torque converter nuts. Tighten to 44 Nm (32 lb-ft).
20. Install the access cover and the 2 pin-type retainers.
21. Install the starter motor. For additional information, refer to «STARTING SYSTEM»(ref-574163) .
22. NOTE: RH shown in illustration, LH similar. Install the front crossmember brace and the 4 nuts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
23. NOTE: Do not lubricate the engine oil filter gasket. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
24. Raise the underbody shield and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
25. Position the A/C compressor and install the bolt and stud bolt. Do not torque at this time.
26. Install the A/C compressor stud and nut. Tighten the stud to 9 Nm (80 lb-in). Tighten the nut to 26 Nm (19 lb-ft).
27. Tighten the A/C compressor bolt and stud bolt. Tighten the nut to 26 Nm (19 lb-ft).
28. Attach the wiring harness retainer to the A/C compressor stud bolt.
29. If equipped, connect the block heater electrical connector.
30. Install the wiring harness bracket on the LH valve cover stud bolt and install the nut. Tighten to 10 Nm (89 lb-in).
31. Connect the generator electrical connector. Attach the generator wiring harness retainer to the valve cover and valve cover stud bolt.
32. Connect the generator B+ cable and install the nut. Tighten to 17 Nm (150 lb-in).
33. NOTE: RH shown in illustration, LH similar. Connect and attach the RH and LH Heated Oxygen Sensor (HO2S) electrical connectors.
34. Connect the 2 heater hose couplings (1 shown in illustration) at the RH rear of the engine. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-574127) .
35. Connect the middle PCM electrical connector. Attach the PCM wiring harness pin-type retainer.
36. Connect the engine wiring harness electrical connector. Attach the wiring harness pin-type retainer to the bracket.
37. Connect the brake booster vacuum hose to the engine.
38. Attach the fuel supply tube and EVAP tube retainer to the LH valve cover.
39. Position and connect the Evaporative Emission (EVAP) tube to the intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-574171) . Attach the EVAP tube retainer to the intake manifold.
40. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-574171) .
41. Connect the upper and lower radiator hoses to the thermostat housing.
42. NOTE: RH shown in illustration, LH similar. Install the RH and LH engine mount bracket-to-engine mount nuts. Tighten to 63 Nm (46 lb-ft).
43. Install the accessory drive belt and A/C compressor belt. For additional information, refer to «ACCESSORY DRIVE»(ref-574129) .
44. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-574172) .
45. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-574156) .
46. Lift the cowl screen and install the ground strap and bolt. Tighten to 10 Nm (89 lb-in). Attach the wiring harness retainer to the cowl.
47. Install the 2 LH cowl vent screen plastic rivets.
48. If equipped, install the engine appearance cover.
49. NOTE: LH shown in illustration, RH similar. If equipped, install the strut tower cross brace and the 4 nuts (2 shown in illustration). Tighten to 35 Nm (26 lb-ft).
50. NOTE: RH shown in illustration, LH similar. Align the hood and install the 4 bolts (2 shown in illustration). Tighten to 12 Nm (106 lb-in).
51. Connect the 2 windshield washer hose C-Lock Couplers and attach the 2 windshield washer hose retainers. For additional information, refer to «WIPERS AND WASHERS»(ref-574161) .
52. Attach the 2 windshield washer hose retainers and install the 8 hood insulation pin-type retainer (2 shown in illustration).
53. Fill the engine with clean engine oil.
54. Fill the engine cooling system. For additional Information, refer to «ENGINE COOLING SYSTEM -- MUSTANG»(ref-574172) .
55. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-574143) .
56. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

Engine - Manual Transmission

SPECIAL TOOLS 2, 200# Floor Crane, Fold Away 300-OTC1819E Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 355

MATERIAL SPECIFICATIONS

1. NOTE: Before installing the transmission, the input shaft must be cleaned and lubricated with a small amount of multi-purpose grease. Using the Floor Crane and Spreader Bar, position the engine in the engine compartment.
2. Align the engine to the transmission and install LH bellhousing-to-oil pan bolt. Tighten the bolt, it will be torqued at a later step.
3. Install the engine-to-bellhousing bolt. Tighten the bolt, it will be torqued at a later step.
4. Install the RH engine mount bracket, bolt and 2 stud bolts (2 shown in illustration). Tighten to 55 Nm (41 lb-ft).
5. Install the LH engine mount bracket and the 3 bolts (2 shown in illustration). Tighten to 55 Nm (41 lb-ft).
6. Install the 4 upper bellhousing-to-engine bolt and stud bolts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
7. Attach the 2 wiring harness retainers (1 shown in illustration) to the upper transmission stud bolts.
8. Install the ground wire and the bolt on the rear of the cylinder head. Tighten to 10 Nm (89 lb-in).
9. Install the oil pan-to-bellhousing bolt. Tighten to 48 Nm (35 lb-ft).
10. Tighten the engine-to-bellhousing bolt. Tighten to 48 Nm (35 lb-ft).
11. Install the LH bellhousing-to-engine bolt and LH bellhousing-to-oil pan stud bolt. Tighten to 48 Nm (35 lb-ft).
12. Tighten the LH bellhousing-to-oil pan bolt. Tighten to 48 Nm (35 lb-ft).
13. Remove the 3 bolts and lower the underbody shield.
14. Position the wiring harness retainer on the RH front engine mount bracket stud bolt.
15. Position the wiring harness retainer on the RH rear engine mount bracket stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
16. NOTE: LH shown in illustration, RH similar. Install the new 2 LH and RH catalytic convertor-to-exhaust manifold nuts. Tighten to 45 Nm (35 lb-ft).
17. Install the access cover and the 2 pin-type retainers.
18. Install the starter motor. For additional information, refer to «STARTING SYSTEM»(ref-574163) .
19. NOTE: RH shown in illustration, LH similar. Install the front crossmember brace and the 4 nuts (2 shown in illustration). Tighten to 48 Nm (35 lb-ft).
20. NOTE: Do not lubricate the engine oil filter gasket. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
21. Raise the underbody shield and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
22. Position the A/C compressor and install the bolt and stud bolt. Do not torque at this time.
23. Install the A/C compressor stud and nut. Tighten the stud to 9 Nm (80 lb-in). Tighten the nut to 26 Nm (19 lb-ft).
24. Tighten the A/C compressor bolt and stud bolt. Tighten the nut to 26 Nm (19 lb-ft).
25. Attach the wiring harness retainer to the A/C compressor stud bolt.
26. If equipped, connect the block heater electrical connector.
27. Install the wiring harness bracket on the LH valve cover stud bolt and install the nut. Tighten to 10 Nm (89 lb-in).
28. Connect the generator electrical connector. Attach the generator wiring harness retainer to the valve cover stud bolt.
29. Connect the generator B+ cable and install the nut. Tighten to 17 Nm (150 lb-in).
30. NOTE: RH shown in illustration, LH similar. Connect and attach the RH and LH Heated Oxygen Sensor (HO2S) electrical connectors.
31. Connect the 2 heater hose couplings (1 shown in illustration) at the RH rear of the engine. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-574127) .
32. Connect the middle PCM electrical connector. Attach the PCM wiring harness pin-type retainer.
33. Connect the engine wiring harness electrical connector. Attach the wiring harness pin-type retainer to the bracket.
34. Connect the brake booster vacuum hose to the engine.
35. Attach the fuel supply tube and EVAP tube retainer to the LH valve cover.
36. Position and connect the Evaporative Emission (EVAP) tube to the intake manifold. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-574171) . Attach the EVAP tube retainer to the intake manifold.
37. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-574171) .
38. Connect the upper and lower radiator hoses to the thermostat housing.
39. NOTE: RH shown in illustration, LH similar. Install the RH and LH engine mount bracket-to-engine mount nuts. Tighten to 63 Nm (46 lb-ft).
40. Install the accessory drive belt and A/C compressor belt. For additional information, refer to «ACCESSORY DRIVE»(ref-574129) .
41. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-574172) .
42. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-574156) .
43. Lift the cowl screen and install the ground strap and bolt. Tighten to 10 Nm (89 lb-in). Attach the wiring harness retainer to the cowl.
44. Install the 2 LH cowl vent screen plastic rivets.
45. If equipped, install the engine appearance cover.
46. NOTE: LH shown in illustration, RH similar. If equipped, install the strut tower cross brace and the 4 nuts (2 shown in illustration). Tighten to 35 Nm (26 lb-ft).
47. NOTE: RH shown in illustration, LH similar. Align the hood and install the 4 bolts (2 shown in illustration). Tighten to 12 Nm (106 lb-in).
48. Connect the 2 windshield washer hose C-Lock Couplers and attach the 2 windshield washer hose retainers. For additional information, refer to «WIPERS AND WASHERS»(ref-574161) .
49. Attach the 2 windshield washer hose retainers and install the 8 hood insulation pin-type retainer (2 shown in illustration).
50. Fill the engine with clean engine oil.
51. Fill the engine cooling system. For additional Information, refer to «ENGINE COOLING SYSTEM -- MUSTANG»(ref-574172) .
52. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-574143) .
53. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.