Engine - 4.6L (3V): Overhaul — Engine - 4.6L (3V) — Mechanical

Disassembly

Remove the bolts and the variable camshaft timing (VCT) housing. Discard the gasket.
Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft. NOTE: The camshaft must be installed in the head to use the special tool necessary to compress the valve springs. NOTE: Lubricate the camshaft bearing caps with clean engine oil.
Install the camshaft bearing caps in their original locations. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts finger-tight.
Using the special tool, compress the valve spring and remove the valve spring retainer keys. see scheme 375: Compressing Valve Spring With Special Tool
Remove the valve spring retainer, the valve spring and the valve seal. Discard the valve seal.
Remove the valve from the cylinder head.
Repeat the previous 3 steps for each valve.
Inspect the components. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-256466). CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from sideloading.
Remove the bolts and the front camshaft bearing cap and then the remaining bearing caps.
Remove the camshaft.
Check the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-256466).

Assembly

Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft. NOTE: Lubricate the camshaft bearing caps with clean engine oil.
Install the camshaft bearing caps in their original locations. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts finger-tight. NOTE: Lubricate the valve stem with clean engine oil prior to installation.
Install the valve into the cylinder head. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation.
Position a new valve seal onto the valve stem.
Using the special tool, install the new valve seal. see scheme 376: Installing Valve Seal Using Special Tool
Using the special tool, install the valve spring, the valve spring retainer and the valve spring retainer keys. see scheme 377: Compressing Valve Spring With Special Tool
Repeat the previous 2 steps for each valve.
Remove the bolts and the front camshaft bearing cap and then the remaining bearing caps.
Remove the camshaft.
Install a new gasket, the variable camshaft timing (VCT) housing and the bolts. Tighten to 10 Nm (89 lb-in).

Remove the piston rings from the piston. Discard the piston rings.
Remove the piston pin retainers and the piston pin.
Separate the piston from the connecting rod.
Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-256466) .

Note. The connecting rod must be installed into the piston with identification markings toward the front.

Scheme 531

Scheme 531: Assembly

Position the connecting rod in the piston. see scheme 379: Locating Connecting Rod & Piston Identification Marks
Lubricate the piston pin and pin bore with clean engine oil.
Install the piston pin in the piston and connecting rod assembly.
Install the piston pin retaining clips in the piston.
Lubricate the piston and the new piston rings with clean engine oil.
Install the piston rings onto the piston.

SPECIAL TOOLS REFERENCE Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Installer, Connecting Rod 303-442 (T93P-6136-A) Compressor, Valve Spring 303-1039 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Crankshaft Front Seal 303-635 Installer, Front Cover Seal 303-335 (T88T-6701-A) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Oil Slinger 303-517 (T95P-6701-CH) Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH) Alignment Pins, Cylinder Head 303-1040 (SR-015486) Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Locking Tool, Camshaft Phaser Sprocket 303-1046

Scheme 532

Scheme 532: Engine

Scheme 533

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Scheme 536

Item	Specification
Motorcraft Metal Surface Prep ZC-31
Silicone Gasket Remover ZC-30
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Gasket Maker TA-16	WSK-M2G348-A5
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent	WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent (yellow color)	WSS-M97B51-A1
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA

MATERIAL

Scheme 537

Fig. 380: Identifying Engine - Upper End Components With Torque Specifications

Scheme 380: Identifying Engine - Upper End Components With Torque Specifications

Scheme 538

Fig. 381: Identifying Engine - Lower End Components With Torque Specifications (1 Of 2)

Scheme 381: Identifying Engine - Lower End Components With Torque Specifications (1 Of 2)

Scheme 539

Fig. 382: Identifying Engine - Lower End Components With Torque Specifications (2 Of 2)

Scheme 382: Identifying Engine - Lower End Components With Torque Specifications (2 Of 2)

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Record the main bearing code found on the front of the engine block. see scheme 383: Identifying Main Bearing Code Found On Front Of Engine Block
Record the main bearing code found on the back of the crankshaft. see scheme 384: Identifying Main Bearing Code Found On Back Of Crankshaft
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing. 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 for the number 1 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2". Repeat this process for the remaining 4 main bearings. see scheme 385: Bearing Select Fit Chart (Standard Bearings)
If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing. see scheme 386: Bearing Select Fit Chart (Oversize Bearings) 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.
Install the crankshaft main bearings. Install the crankshaft upper main bearings into the cylinder block. Install the crankshaft lower main bearings into the bearing caps. Make sure all oil passages are aligned. Lubricate all main bearings with clean engine oil.
Lubricate the crankshaft bearing journals with clean engine oil. Install the crankshaft onto the upper crankshaft main bearings. see scheme 387: Installing Crankshaft Onto Upper Crankshaft Main Bearings NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against 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. see scheme 388: Pushing Crankshaft Rearward see scheme 389: Installing Rear Crankshaft Upper Thrust Washer
Install the rear (No. 5) main bearing cap.
Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position. see scheme 390: Installing Crankshaft Lower Main Bearings
Install the vertical main bearing cap fasteners and tighten in the sequence shown, in 4 stages. Stage 1: Tighten fasteners 1 through 20 to 10 Nm (89 lb-in). Stage 2: Tighten fasteners 1 through 10 to 25 Nm (18 lb-ft). Stage 3: Tighten fasteners 11 through 20 to 40 Nm (30 lb-ft). Stage 4: Tighten fasteners 1 through 20 an additional 90 degrees. see scheme 391: Installing Vertical Main Bearing Cap Fasteners
Install the cross-mounted main bearing cap fasteners and tighten in the sequence shown, in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. see scheme 392: Installing Cross-Mounted Main Bearing Cap Fasteners
Check the crankshaft end play. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-256466).
Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-256466).
Assemble the pistons. For additional information, refer to «PISTON»(ref-256454-S14234908722007061500000) in this article.
Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston. see scheme 393: Identifying Piston Ring Gap CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only 1 connecting rod, rod bearing and piston is shown.
Use the special tools to install the connecting rod with the upper connecting rod bearing in place. Lubricate the piston and ring with clean engine oil Lubricate the rod bearings with clean engine oil. see scheme 394: Using Special Tools To Install Piston And Connecting Rod Assembly CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Once the connecting rod is seated on the crankshaft journal, remove the special tools. see scheme 395: Identifying Special Tool (303-442) CAUTION: The rod cap installation must keep the same orientation as marked during disassembly. NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
Position the lower bearing and connecting rod and install the new bolts loosely. NOTE: Main bearing caps are removed for clarity.
Tighten the bolts in 2 stages, in the sequence shown. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees. see scheme 396: Identifying Tighten Sequence Of Connecting Rod Bearing Caps
Position the oil pump and install the 3 bolts. Tighten to 10 Nm (89 lb-in). see scheme 397: Locating Oil Pump Bolts
Install the windage tray and the 7 nuts. Tighten to 25 Nm (18 lb-ft). see scheme 398: Locating Windage Tray And Nuts CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil prior to installation.
Install the spacer, oil pump screen and pickup tube and the 3 bolts. Tighten the spacer and the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft). Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in). see scheme 399: Identifying Spacer, Oil Pump Screen And Pickup Tube And Bolts CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused. NOTE: Do not turn the crankshaft until instructed to do so. NOTE: LH shown, RH similar.
Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 cylinder head bolts loosely. see scheme 400: Positioning Cylinder Head Gaskets And Cylinder Heads Over Dowels NOTE: LH shown, RH similar.
Tighten the bolts in 3 stages, in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees. see scheme 401: Identifying Cylinder Head Bolt Tightening Sequence
Remove the special tool from the LH cylinder head. see scheme 402: Identifying Special Tool Onto Cylinder Head
Remove the special tool from the RH cylinder head. see scheme 403: Identifying Special Tool On Cylinder Head NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
Install the hydraulic lash adjusters into the RH and LH cylinder heads. see scheme 404: Identifying Hydraulic Lash Adjusters NOTE: Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
Install the LH and RH camshafts. NOTE: LH shown, RH similar. NOTE: Lubricate the camshaft bearing caps with clean engine oil.
Install the LH and RH camshaft bearing caps in their original locations. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely. Tighten to 10 Nm (89 lb-in) in the sequence shown. see scheme 405: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequence CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: LH shown, RH similar.
Position the camshaft phaser sprockets and install new camshaft phaser bolts finger tight. see scheme 406: Identifying Camshaft Phaser And Sprocket Assembly Bolt CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: LH shown, RH similar.
Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. see scheme 407: Identifying Special Sprocket Phaser Tool
Install the crankshaft sprocket, making sure the flange faces forward. see scheme 408: Identifying Crankshaft Sprocket
Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o'clock position. see scheme 409: Rotating Crankshaft To Position Crankshaft Sprocket Timing Mark In 6 O'Clock Position
Rotate the camshaft sprockets to position the RH camshaft sprocket timing mark in the 11 o'clock position and the LH camshaft sprocket timing mark in the 12 o'clock position. see scheme 410: Rotating Camshaft Sprockets CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body, or permanent compression of the seal bead, will require replacement of the tensioner.
Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
Compress the tensioner plunger, using a vise. see scheme 411: Compressing Tensioner Plunger
Install a retaining clip on the tensioner to hold the plunger in during installation. see scheme 412: Identifying Retaining Clip on Tensioner
Remove the tensioner from the vise.
If the copper links are not visible, mark one link on one end and one link on the other end and use as timing marks. see scheme 413: Identifying Timing Chain Copper Links
Install the 4 bolts and the LH and RH timing chain guides. Tighten to 10 Nm (89 lb-in). see scheme 414: Identifying Timing Chain Guides
Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain. see scheme 415: Aligning Crankshaft Sprocket Timing Mark And LH Timing Chain Link NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link. see scheme 416: Aligning Camshaft Sprocket Timing Mark With Copper Link NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft). see scheme 417: Identifying LH Timing Chain Tensioner & Tensioner Arm
Remove the retaining clip from the LH timing chain tensioner. (Scheme 531): View Of Retaining Clip AndTiming Chain Tensioner
Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link. (Scheme 532): Aligning Crankshaft Sprocket Timing Mark And RH Timing Chain Link NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link. (Scheme 533): Positioning RH Timing Chain On Camshaft Sprocket
Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft). (Scheme 534): Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
Remove the retaining clip from the RH timing chain tensioner. (Scheme 535): View Of Retaining Clip AndTiming Chain Tensioner NOTE: The RH and LH camshaft phaser sprockets are similar. Refer to the single timing mark to identify the RH camshaft phaser sprocket and the L timing mark to identify the LH camshaft phaser sprocket.
As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note. (Scheme 536): Identifying Chains & Sprockets Timing Marks
Install the crankshaft sensor ring on the crankshaft. (Scheme 537): View Of Crankshaft Sensor Ring At Crankshaft NOTE: Lubricate the roller followers with clean engine oil prior to installation.
Using the special tool, install all of the camshaft roller followers. (Scheme 538): Compressing Spring Using Special Tool CAUTION: 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: If the engine front cover is 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. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown. (Scheme 539): Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight. (Scheme 540): Identifying Engine Front Cover And Alignment Dowels
Tighten the 15 engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft). ENGINE FRONT COVER FASTENERS SEQUENCE Item Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 6 W706508 Stud, Hex Shoulder Pilot, M8 x 1.25 x 50 - M6 x 1 x 10 7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 - M6 x 1 x 86.35 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 11 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 12 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 13 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 14 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 15 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 (Scheme 541): Identifying Tightening Sequence Of Engine Front Cover Fasteners
Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil. (Scheme 542): Locating Crankshaft Front Seal
Using the special tools, install the crankshaft front oil seal into the engine front cover. (Scheme 543): Installing Crankshaft Front Seal Using Special Tools NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. 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.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley. (Scheme 544): Applying Silicone Gasket And Sealant To Woodruff Key Slot In Crankshaft Pulley
Using the special tool, install the crankshaft pulley. (Scheme 545): Installing Crankshaft Pulley
Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees. NOTE: Do not reuse the O-ring seals. NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation.
Slide the coolant tube forward with the new O-ring seals into the cylinder block. (Scheme 546): Locating Coolant Tube
Install the coolant tube stud bolt. Tighten to 10 Nm (89 lb-in). (Scheme 547): Locating Coolant Tube Stud Bolt CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur. NOTE: Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
Position the coolant pump and install the 4 bolts loosely. (Scheme 548): Identifying Coolant Pump
Tighten the 4 coolant pump bolts. Tighten to 25 Nm (18 lb-ft). (Scheme 549): Identifying Coolant Pump Bolts
Position the accessory drive belt tensioner and install the 3 bolts. Tighten to 25 Nm (18 lb-ft). (Scheme 550): Identifying Accessory Drive Belt Tensioner Bolts
Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts. Tighten to 25 Nm (18 lb-ft). (Scheme 551): Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts
Install the crankshaft position (CKP) sensor and the bolt. Tighten to 10 Nm (89 lb-in). (Scheme 552): Locating Crankshaft Position (CKP) Sensor Bolt NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install the LH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in). (Scheme 553): Locating Camshaft Position (CMP) Sensor And Bolt NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install the RH CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in). see scheme 441: Locating CMP Sensor And Bolt
Install the knock sensor (KS) and the bolts. Tighten to 20 Nm (15 lb-ft). (Scheme 554): Locating Knock Sensor (KS) And Bolts CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. (Scheme 555): Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
Position the RH valve cover and gasket on the cylinder head and tighten the 14 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in). (Scheme 556): Identifying Tightening Sequence Of Valve Cover Bolts CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. (Scheme 557): Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
Position the LH valve cover and gasket on the cylinder head and tighten the 15 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in). see scheme 446: Identifying Tighten Sequence Of Valve Cover Bolts
Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown. Tighten to 25 Nm (18 lb-ft). see scheme 447: Identifying Exhaust Manifold Bolt Torque Sequence
Install the RH motor mount bracket, 2 bolts and 2 stud bolts. Tighten to 55 Nm (41 lb-ft). (Scheme 558): Locating Motor Mount Bracket Bolts
Install the oil level indicator tube and the bolt. Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation. Tighten to 10 Nm (89 lb-in). see scheme 449: Locating Oil Level Indicator Tube Bolt
Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown. Tighten to 25 Nm (18 lb-ft). see scheme 450: Identifying Exhaust Manifold Bolt Torque Sequence
Install the LH motor mount bracket and 4 bolts. Tighten to 55 Nm (41 lb-ft). see scheme 451: Locating Motor Mount Bracket And Bolts CAUTION: 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 and inspect the mating surfaces and install new gaskets.
Position the oil filter adapter and install the 4 bolts. Tighten to 25 Nm (18 lb-ft). see scheme 452: Locating Oil Filter Adapter And Bolts
Install a new oil filter. NOTE: LH shown, RH similar.
Install the 8 ignition coils and the 8 bolts. Tighten to 6 Nm (53 lb-in). (Scheme 559): Identifying Ignition Coils And Bolts
Install the ground strap and nut to the stud bolt. Tighten to 10 Nm (89 lb-in). (Scheme 560): Locating Ground Strap And Nut On Stud Bolt
Position the engine wiring harness on the engine.
Connect the engine oil pressure sensor electrical connector. see scheme 455: Locating Engine Oil Pressure Sensor Electrical Connector
Attach the engine wiring harness retainer to the stud bolt. Connect the LH heated oxygen sensor (HO2S) electrical connector. see scheme 456: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Connect the knock sensor (KS) electrical connector and pin-type retainer. see scheme 457: Locating Knock Sensor (KS) Electrical Connector And Pin-Type Retainer
Attach the CHT sensor jumper harness electrical connector pin-type retainer. see scheme 458: Identifying Cylinder Head Temperature (CHT) Sensor Jumper Harness Electrical Connector
Connect the CHT sensor electrical connector. see scheme 459: Locating CHT Sensor Electrical Connector
Detach the engine wiring harness pin-type retainers. (Scheme 561): Locating Engine Wiring Harness Pin-Type Retainers
Connect the 2 engine wiring harness retainers to the LH valve cover studs. see scheme 461: Locating Engine Wiring Harness Retainers
Connect the 2 engine wiring harness retainers to the RH valve cover studs. see scheme 462: Locating Engine Wiring Harness Retainers At RH Valve Cover NOTE: RH shown, LH similar.
Connect the 4 RH and 4 LH ignition coil electrical connectors. see scheme 463: Locating Ignition Coil Electrical Connectors
Connect the positive crankcase ventilation (PCV) tubes from the RH and LH valve covers. (Scheme 562): Locating Positive Crankcase Ventilation Tubes
Install the RH radio ignition interference capacitor and nut. Tighten to 10 Nm (89 lb-in). see scheme 465: Installing RH Radio Ignition Interference Capacitor And Nut
Attach the engine wiring harness pin-type retainers. see scheme 466: Locating Engine Wiring Harness Pin-Type Retainers NOTE: RH shown, LH similar.
Connect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors. (Scheme 563): Locating Camshaft Timing (VCT) Solenoid Electrical Connectors NOTE: RH shown, LH similar.
Connect the RH and LH camshaft position (CMP) sensor electrical connectors. see scheme 468: Identifying RH CMP Sensor Electrical Connector
Install the special tool. see scheme 469: Identifying Special Tool (303-F047)
Using a suitable floor crane, remove the engine from the engine stand. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker must be applied to the rear crankshaft seal retainer mating surface on the engine block.
Apply a bead of gasket maker to the rear crankshaft seal retainer mating surface on the engine block. (Scheme 564): Applying Bead Of Gasket Maker To Rear Crankshaft Seal Retainer Mating Surface On Engine Block
Install the crankshaft rear seal retainer plate and loosely install the 6 bolts. (Scheme 565): Identifying Crankshaft Rear Oil Seal Retainer
Tighten the 6 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in). (Scheme 566): Identifying Bolt Tightening Sequence CAUTION: 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.
Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface. (Scheme 567): Area For Applying Bead Of Silicone Gasket And Sealant 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 silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface. see scheme 474: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
Install the oil pan gasket and the oil pan and loosely install the 16 bolts. (Scheme 568): Identifying Oil Pan And Gasket
Tighten the 16 bolts in 3 stages, in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees. (Scheme 569): Identifying Oil Pan Bolt Tightening Sequence NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the special tools, install a new crankshaft rear seal. (Scheme 570): Using Special Tools To Install New Crankshaft Rear Seal
Using the special tools, install the crankshaft rear oil slinger. (Scheme 571): Installing Crankshaft Rear Oil Slinger Using Special Tools NOTE: Flexplate shown, flywheel similar.
Install the flexplate or flywheel and the 6 bolts in the sequence shown. Tighten to 80 Nm (59 lb-ft). see scheme 479: Identifying Flexplate Or Flywheel And Bolts

SPECIAL TOOLS REFERENCE 3-Bar Engine Support Kit 303-F072 Lifting Brackets, Engine 303-050 (T70P-6000) Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent

Scheme 597

Scheme 597: Engine

Scheme 598

Scheme 599

Item	Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent	WSS-M2C930-A