Engine Mechanical - 5.8L (4V): Overhaul Ford Mustang V рестайлинг 2

Intake Manifold Assembly

MATERIAL SPECIFICATIONS

Scheme 799

Scheme 800

Scheme 801

Disassembly

1. Remove the heater hose.
2. Remove the Supercharger (SC) bubbler hose.
3. Remove the upper and lower SC bypass actuator vacuum tubes.
4. Remove the 2 bolts and the EGR system module. Discard the gasket.
5. Disconnect the vacuum tube from the fuel rail and pressure temperature sensor.
6. Remove the 4 fuel rail bolts. Remove the fuel rail and injectors as an assembly.
7. Remove the 8 fuel injector clips and the 8 fuel injectors from the fuel rail. Discard the 8 fuel injector clips.
8. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse the O-ring seals. Remove and discard the 16 fuel injector O-ring seals.
9. Remove the 10 bolts and the SC. Discard the gasket.
10. Remove the vacuum tube.
11. Remove the Intake Air Temperature 2 (IAT2) sensor.
12. Remove the 5 bolts and the Charge Air Cooler (CAC) tube assembly. Discard the gasket.
13. Remove the 2 CAC coolant connector tubes. Discard the O-ring seals.
14. Remove the 13 bolts and the lower intake manifold cover. Discard the gasket.
15. Remove the 10 bolts, the 2 CAC rail supports and the CAC.

Scheme 802

Scheme 803

Scheme 804

1. 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. NOTE: Apply threadlock and sealer to the CAC bolts prior to installation. Position the CAC, the 2 CAC rail supports and install the 10 bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
2. Install a new gasket, the lower intake manifold cover and the 13 bolts. Tighten in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
3. NOTE: Apply clean engine coolant to the new CAC coolant connector tube O-ring seals. Install new O-ring seals on the CAC coolant connector tubes. Install the CAC coolant connector tubes.
4. Install a new gasket, the CAC coolant tube assembly and the 5 bolts. Tighten to 10 Nm (89 lb-in).
5. Install the IAT2 sensor. Tighten in 2 stages. Stage 1: Tighten to 15 Nm (133 lb-in). Stage 2: Tighten the IAT2 sensor until the locking section of the sensor is pointing outward.
6. Install the vacuum tube.
7. Install a new gasket, the SC and the 10 bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
8. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation. Install new O-ring seals on each of the fuel injectors.
9. Install the 8 fuel injectors onto the fuel rail and install 8 new fuel injector clips.
10. Install the fuel rail and fuel injector assembly onto the intake manifold.
11. Install the 4 fuel rail bolts. Tighten to 10 Nm (89 lb-in).
12. Connect the vacuum tube to the fuel rail and pressure temperature sensor.
13. Install a new gasket, the EGR system module and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
14. Install the upper and lower SC bypass actuator vacuum tubes.
15. Install the SC bubbler hose.
16. Install the heater hose.

1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the piston pin retainers and the piston pin.
3. 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) .

Scheme 805

1. NOTE: The connecting rod must be installed into the piston with identification markings toward the front. 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 piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston.

SPECIAL TOOLS Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Compressor, Valve Spring 303-452 (T93P-6565-AR) 2, 200# Floor Crane, Fold Away 014-00071 or equivalent Holding Tool, Crankshaft 303-448 (T93P-6303-A) Installer, Connecting Rod 303-442 (T93P-6136-A) Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Lifting Bracket, Engine 303-D089 (D93P-6001-A3) or equivalent Lifting Bracket, Engine (2 required) 303-D087 (D93P-6001-A1) or equivalent Strap Wrench 303-D055 (D85L-6000-A) or equivalent

Scheme 806

Scheme 807

Scheme 808

MATERIAL SPECIFICATIONS

Scheme 809

Scheme 810

Oil Filter Adapter Assembly

Note. The engine will be equipped with either a oil cooler or an oil cooler thermostat.

Scheme 811

Scheme 812

Scheme 813

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, can cause engine failure.

Note. During engine assembly it may become necessary to check bearing clearances and end play. Refer to ENGINE SYSTEM - GENERAL INFORMATION .

Scheme 814

Scheme 815

Scheme 816

Scheme 817

Scheme 818

Scheme 819

Scheme 820

Scheme 821

Scheme 822

Scheme 823

Scheme 824

Scheme 825

Scheme 826

Scheme 827

Scheme 828

Scheme 829

Scheme 830

Scheme 831

Scheme 832

Scheme 833

Scheme 834

Scheme 835

Scheme 836

Scheme 837

1. Install the 8 oil squirters. Tighten to 4 Nm (35 lb-in).
2. Record the first character code information on the cylinder block.
3. Note the first character on the No. 7 crankshaft counterweight.
4. Using the data recorded in the previous 2 steps, cross-reference using the chart to obtain bearing grade.
5. 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 into the cylinder block.
6. 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.
7. NOTE: Make sure the side of the thrust washer, with three 5-mm 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. 5 main boss.
8. NOTE: Make sure the side of the thrust washer, with three 5-mm 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. 5 main boss.
9. NOTE: Make sure the side of the thrust washer, with three 5-mm 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. 5 main bearing cap, with the tab aligned with the cutout in the main bearing cap.
10. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new cap fasteners.
11. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.
12. Install 30 new crankshaft main bearing cap fasteners hand tight.
13. Tighten the 10 new outside vertical main bearing cap fasteners in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 40 Nm (30 lb-ft). Stage 3: Tighten an additional 90 degrees.
14. Tighten the 10 new inside vertical main bearing cap fasteners in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 40 Nm (30 lb-ft). Stage 3: Tighten an additional 90 degrees.
15. Tighten the 10 new side bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
16. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
17. Check the crankshaft end play. Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-574124) .
18. NOTE: Verify correct orientation of connecting rod and rod cap. Prepare the connecting rod and cap. Insert the bolts in the rod cap. Insert the upper and lower rod bearings into the rod and cap.
19. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown in illustration. NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine. Using the Piston Ring Compressor and the Connecting Rod Installer, install the No. 1 and No. 6 piston and the connecting rod assemblies. Lubricate the piston and rings with clean engine oil. Lubricate the rod bearings with clean engine oil. Lubricate the cylinder bores with clean engine oil.
20. Seat the connecting rods on the crankshaft journals and remove the Connecting Rod Installer.
21. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or damage to the engine may occur. NOTE: Rotate the crankshaft after each connecting rod is installed and tightened, to check for assembly binding. Install the rod bearing caps and the rob bearing cap bolts. Tighten the bolts in 3 stages. Stage 1: Tighten to 25 Nm (30 lb-ft). Stage 2: Tighten to 33 Nm (30 lb-ft). Stage 3: Tighten an additional 90 degrees.
22. Install the piston assemblies 3 and 5, 4 and 7, 2 and 8, by turning the crankshaft 90 degrees and repeating the previous steps.
23. NOTE: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. Failure to follow these instructions may result in engine damage. For additional information, refer to «CYLINDER HEAD»(ref-574174-S25504893902013082300000) . NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage. NOTE: The new gasket has a film coating which is crucial to the ability of the gasket to seal correctly. Do not scratch the gasket. NOTE: RH head gasket shown in illustration, LH head gasket similar. Install the RH and LH head gasket over the dowel pins.
24. NOTE: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area. Failure to follow these instructions may result in engine damage. NOTE: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation. Failure to follow these instructions may result in engine damage. NOTE: LH shown in illustration, RH similar. Install the RH and LH cylinder heads on the dowels and the head gaskets. Loosely install new bolts.
25. Tighten the new RH cylinder head bolts in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 50 Nm (37 lb-ft). Stage 3: Tighten an additional 90 degrees. Stage 4: Tighten an additional 90 degrees. Stage 5: Tighten an additional 90 degrees.
26. Tighten the new LH cylinder head bolts in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 50 Nm (37 lb-ft). Stage 3: Tighten an additional 90 degrees. Stage 4: Tighten an additional 90 degrees. Stage 5: Tighten an additional 90 degrees.
27. Install the oil pump and 3 bolts. Tighten in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
28. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly. NOTE: LH shown in illustration, RH similar. Compress each tensioner plunger, using an edge of a vise.
29. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
30. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
31. Install a suitable pin into the hole of each tensioner housing to hold the ratchet assembly and plunger in place during installation. Remove the tensioner from the vise.
32. If the colored links are not visible, mark one link on one end and 2 links on the other end, and use as timing marks.
33. Using the Crankshaft Holding Tool, position the crankshaft.
34. Install the crankshaft sprocket with the flange facing forward.
35. Position the camshaft sprocket timing marks as shown in illustration.
36. Install the LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
37. Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one colored link on the timing chain with the slot on the crankshaft sprocket.
38. Install the LH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.
39. Install the LH primary timing chain tensioner arm.
40. Install the LH primary timing chain tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft). Remove the pin from the tensioner.
41. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
42. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored link with the timing marks on the sprocket.
43. Install the RH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.
44. Install the RH primary timing chain tensioner arm.
45. Install the RH primary timing chain tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft). Remove the pin from the tensioner.
46. As a post-check, verify correct alignment of all timing marks. Make sure that the colored links are lined up with the marks on the crankshaft sprocket and the camshaft sprockets.
47. Install the crankshaft washer.
48. Install the crankshaft sensor ring.
49. NOTE: If the components are to be reinstalled, they must be installed in their original positions or damage to the engine may occur. Install the hydraulic lash adjusters.
50. Using the Valve Spring Compressor, compress the valve spring and install the roller follower.
51. Repeat the previous step to install all the roller followers.
52. NOTE: RH shown in illustration, LH similar. Install the 8 spark plugs. Tighten to 18 Nm (159 lb-in).
53. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Apply a bead of Motorcraft® High Performance Engine RTV Silicone to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.
54. NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation. Using new gaskets, install the engine front cover and the 16 bolts. Tighten the bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten bolts 1 through 14 to 25 Nm (18 lb-ft). Stage 2: Tighten bolts 15 and 16 to 48 Nm (35 lb-ft). Item Part Number Description 1 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 2 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 3 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 4 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 5 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 6 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 7 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 8 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 9 N808586 Stud bolt, hex head pilot, M8 x 1.25 x 50 10 N808586 Stud bolt, hex head pilot, M8 x 1.25 x 50 11 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 12 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 13 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 14 N806177 Bolt, hex head pilot, M8 x 1.25 x 53 15 N606063 Bolt, hex flange head pilot, M10 x 1.50 x 55 16 N606063 Bolt, hex flange head pilot, M10 x 1.50 x 55
55. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
56. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and the Crankshaft Front Oil Seal Installer, install the crankshaft front seal.
57. NOTE: If not secured 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Apply Motorcraft® High Performance Engine RTV Silicone to the Woodruff key slot on the crankshaft pulley.
58. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
59. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
60. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer. Tighten the bolt in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 40 Nm (30 lb-ft). Stage 4: Tighten an additional 180 degrees.
61. Install the coolant pump and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
62. Install the Camshaft Position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
63. Install the Crankshaft Position (CKP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
64. Install new gaskets. Make sure the gaskets are correctly seated on the valve cover.
65. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: LH shown in illustration, RH similar. Apply Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder block joints.
66. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Install the RH valve cover and the 10 bolts. Tighten in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
67. NOTE: If the valve covers are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Install the LH valve cover and the 10 bolts. Tighten in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
68. NOTE: LH shown in illustration, RH similar. If equipped, install the LH and RH block drain plugs. Tighten to 14 Nm (124 lb-in).
69. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging. Using a new gasket, install the oil filter adapter and the 8 bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten bolts 1 through 6 to 25 Nm (18 lb-ft). Stage 2: Tighten bolts 7 and 8 to 48 Nm (35 lb-ft).
70. NOTE: A new oil cooler and oil cooler thermostat (if equipped) must be installed or severe damage to the engine can occur. NOTE: Oil cooler shown in illustration, oil cooler thermostat similar. Using new gaskets, install a new oil cooler or the oil cooler thermostat and the 6 bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 9 Nm (80 lb-in). Stage 2: Tighten an additional 60 degrees.
71. Install the coolant tube assembly and the 3 bolts. Tighten to 10 Nm (89 lb-in).
72. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, install the oil level indicator tube, bolt and oil level indicator. Tighten to 10 Nm (89 lb-in).
73. Install the 3 coolant tube assembly bolts. Tighten to 10 Nm (89 lb-in).
74. NOTE: Hand start the studs first. Install 8 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
75. Install new gaskets, the LH exhaust manifold and 8 new nuts. Tighten in the sequence shown in illustration. Tighten to 20 Nm (177 lb-in).
76. Connect the 2 LH Heated Oxygen Sensor (HO2S) wire retainers.
77. Install the LH engine support insulator bracket and the 4 bolts. Tighten to 55 Nm (41 lb-ft).
78. NOTE: Hand start the studs first. Install 8 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
79. Install new gaskets, the RH exhaust manifold and 8 new nuts. Tighten in the sequence shown in illustration. Tighten to 20 Nm (177 lb-in).
80. Install the RH engine support insulator bracket, the 2 stud bolts, and the 2 bolts. Tighten to 55 Nm (41 lb-ft).
81. Install the Knock Sensor (KS) and the 2 bolts. Tighten to 20 Nm (177 lb-in).
82. 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. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging. Using new intake manifold gaskets, install the intake manifold and the 14 bolts. Tighten in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
83. Connect the intake manifold-to-coolant tube assembly hose.
84. Position the wiring harness assembly onto the engine.
85. NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation. Install the 4 LH coil-on-plugs. Connect the 4 LH coil-on-plug electrical connectors.
86. Install the LH coil-on-plug cover and the 2 bolts. Tighten to 10 Nm (89 lb-in).
87. Attach the wiring harness retainers to the LH valve cover stud bolts.
88. Position the LH radio interference capacitor and install the nut. Tighten to 10 Nm (89 lb-in).
89. Connect the 4 LH fuel injector electrical connectors.
90. Connect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
91. Connect the CMP sensor electrical connector.
92. NOTE: Apply a light film of brake dielectric grease to the inside of the coil boots before installation. Install the 4 RH coil-on-plugs. Connect the 4 RH coil-on-plug electrical connectors.
93. Install the RH coil-on-plug cover and 2 stud bolts. Tighten to 10 Nm (89 lb-in).
94. Install the A/C tube support bracket and the nut. Tighten to 9 Nm (80 lb-in).
95. Attach the wiring harness retainers to the RH valve cover stud bolts.
96. Attach the wiring harness retainers to the RH coil-on-plug cover stud bolts.
97. Connect the EGR valve electrical connector.
98. Position the RH radio interference capacitor and install the nut. Tighten to 10 Nm (89 lb-in).
99. Connect the fuel rail pressure and temperature sensor electrical connector.
100. Connect the 4 RH fuel injector electrical connectors.
101. Connect the PCV valve electrical connector.
102. Attach the 2 wiring harness pin-type retainers.
103. Install the wiring harness retaining bracket and the 2 bolts. Tighten to 10 Nm (89 lb-in).
104. Connect the KS electrical connector.
105. Connect the bubbler hose to the Supercharger (SC).
106. Attach the 2 wiring harness pin-type retainers (1 shown in illustration) to the coolant tube assembly bracket.
107. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
108. Install a new gasket, the Throttle Body (TB) and spacer assembly and the 4 bolts. Tighten to 10 Nm (89 lb-in).
109. Connect the EVAP Evaporative Emission (EVAP) canister purge valve electrical connector.
110. Connect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.
111. Install and connect the crankcase ventilation tube.
112. Install the ground wire and the bolt to the rear of the LH cylinder head. Tighten to 10 Nm (89 lb-in).
113. NOTE: Hand start the top fitting first. Install the EGR tube. Tighten to 43 Nm (32 lb-ft).
114. Install the 3 SC drive belt idler pulleys and the 3 bolts. Tighten the heavy load idler pulley (closest to centerline of engine) to 48 Nm (35 lb-ft). Tighten the smooth idler pulley and the grooved idler pulley to 25 Nm (18 lb-ft).
115. Using the Strap Wrench, install the coolant pump pulley and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
116. Install the accessory drive belt idler pulley (grooved) and the bolt. Tighten to 25 Nm (18 lb-ft).
117. Install the accessory drive belt idler pulley (smooth) and the stud bolt. Tighten to 25 Nm (18 lb-ft).
118. Install the accessory drive belt idler pulley and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
119. Install the accessory drive belt tensioner and the bolt. Tighten to 25 Nm (18 lb-ft).
120. Install the generator and the 3 bolts. Tighten to 48 Nm (35 lb-ft).
121. Connect the coolant hose to the Charge Air Cooler (CAC).
122. Install the thermostat housing assembly and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
123. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
124. Connect the 2 upper radiator hoses to the intake manifold.
125. Install the engine vent hose from the intake manifold.
126. If equipped, install the coolant tube and the coolant tube bracket nut. Tighten to 9 Nm (80 lb-in).
127. If equipped, connect the coolant hose to the thermostat housing.
128. If equipped, connect the coolant hose to the oil cooler.
129. Install the Engine Lifting Bracket.
130. Install the Engine Lifting Bracket.
131. Using the Floor Crane and the Engine Lifting Bracket, remove the engine from the work stand.
132. Apply a 4 mm (0.15 in) bead of Motorcraft® High Performance Engine RTV Silicone to the rear crankshaft seal retainer mating surface on the engine block.
133. NOTE: If not secured 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Install the crankshaft rear seal retainer plate and the 6 bolts. Tighten in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
134. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil. Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear seal.
135. Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear seal.
136. Install the oil pump screen and pickup tube spacer. Tighten to 25 Nm (18 lb-ft).
137. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Clean and inspect the mating surfaces of the engine block and oil pan.
138. 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: If the oil pan is not installed and the fasteners tightened within 5 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. If this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque all of the fasteners within 1 hour of applying the sealer. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.
139. Position the oil pan baffle and gasket.
140. NOTE: The 2 oil pump screen and pickup tube-to-oil pump bolts must be tightened prior to tightening the oil pump screen and pickup tube-to-spacer bolt. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts. Tighten to 10 Nm (89 lb-in).
141. Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
142. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. NOTE: Fastener locations 11, 12 and 13 are stud bolts. Install the oil pan, 13 bolts and 3 stud bolts. Tighten in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
143. Install the engine/transmission spacer plate.
144. Position the flywheel on the crankshaft pilot and start the 8 flywheel bolts.
145. Tighten the flywheel bolts evenly in the sequence shown in illustration to fully seat the flywheel on the crankshaft pilot. Tighten to 80 Nm (59 lb-ft).