Engine - 3.5L: Other Lincoln MKX I

Exhaust Emission Control System

Operation and required maintenance of the exhaust emission control devices used on this engine is covered in the Introduction - Gasoline Engines article.

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.

Variable Camshaft Timing (VCT) System

The VCT system changes intake camshaft timing dependent on engine speed, load and oil temperature. Oil pressure advances and retards camshaft timing to improve low-speed and high-speed engine performance, engine idle quality and 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 make sure of 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.

Cooling System

The engine cooling system includes the following

1. Radiator
2. Timing chain driven 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

Scheme 24

For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION article. For driveability concerns, refer to the Introduction - Gasoline Engines article.

Valve Clearance Check

1. Remove the valve covers. For additional information, refer to «Valve Cover - LH»(ref-292564-S33714080652008080400000) and «Valve Cover - RH»(ref-292564-S40204582622008080400000) .
2. 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: 0.300-0.400 mm (0.0118-0.0157 in)
3. 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-292564-S40099729322008080400000) .

Scheme 25

Scheme 26

Valve Cover - LH

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Installer, Seal 303-1247/2 Remover, Seal 303-1247/1

Scheme 27

Scheme 28

Scheme 29

Material

Scheme 30

Scheme 31

Valve Cover - RH

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Installer, Seal 303-1247/2 Remover, Seal 303-1247/1

Material

Scheme 32

Scheme 33

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Installer, Front Cover Oil Seal 303-335 Replacer, Crankshaft Damper 303-102 (T74P-6316-B) Strap Wrench 303-D055 (D85L-6000-A)

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Material

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Crankshaft Seal 303-1251 Remover, Oil Seal 303-409 (T92C-6700CH)

Scheme 38

Scheme 39

Material

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number 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)

Scheme 40

Scheme 41

Scheme 42

Material

Engine Front Cover

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Adapter for 205-529 (Handle) 205-153 (T80T-4000-W) Alignment Pins 307-399 Installer, Crankshaft Front Seal 303-1251 Installer, Front Cover Seal 303-335 (T88T-6701-A) Oil Pan Holding Fixture 303-1295 Remover, Front Hub 205-D070 (D93P-1175-B) or equivalent Remover, Halfshaft 205-529 Remover, Oil Seal 303-409 (T92C-6700CH) Replacer, Crankshaft Damper 303-102 (T74P-6312-B) 303-D055 (D85L-6000-A) Strap Wrench

Scheme 43

Scheme 44

Material

Timing Drive Components

Special Tools Illustration Tool Name Tool Number Camshaft Alignment Tool 303-1248

Scheme 45

Oil Filter Adapter

Material

Scheme 46

Scheme 47

Engine Oil Pressure (EOP) Switch

Material

Scheme 48

Exhaust Manifold - LH

Material

Scheme 49

Exhaust Manifold - RH

Material

Scheme 50

Engine Mount

Special Tools Illustration Tool Name Tool Number Oil Pan Holding Fixture 303-1295

Scheme 51

Special Tools Illustration Tool Name Tool Number Camshaft Alignment Tool 303-1248

Camshaft

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Camshaft Alignment Tool 303-1248 Disconnect Tool, Transmission Cooler Tube 307-569 Handle 205-153 (T80T-4000-W) Powertrain Lift 014-00765 Remover, Front Hub 205-D070 (D93P-1175-B) or equivalent Remover, Halfshaft (Extension) 205-243 (T89P-3415-A) Remover, Halfshaft (Plate) 205-290 (T89P-3415-B) Remover, Oil Seal 303-409 (T92C-6700CH) Seal Remover 303-1247/1 Slide Hammer 100-001 (T50T-100-A) Strap Wrench 303-D055 (D85L-6000-A) Tie-Rod End Remover 211-105 Universal Adapter Brackets 014-0001

Material

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-292517) article.
2. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-292527) article.
3. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
4. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
5. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.
6. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.
7. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
8. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
9. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-292545) article.
10. Disconnect the battery harness electrical connector.
11. Remove the nut and disconnect the power feed from the battery terminal.
12. Remove the bolt and the ground wire. Detach the 2 wiring harness retainers from the cowl.
13. Disconnect the vacuum hose from the upper intake manifold.
14. Disconnect the upper evaporative emissions (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
15. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
16. Detach the wiring harness retainer from the transaxle control cable bracket.
17. Disconnect the transaxle control cable from the control lever. Detach the control cable from the bracket.
18. Disconnect the transaxle control electrical connector.
19. If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.
20. Remove the nut and disconnect the A/C pressure tube fitting. Discard the O-ring seal.
21. Remove the safety clip from the A/C fitting. Disconnect the A/C suction tube fitting.
22. Disconnect the hose from the power steering reservoir.
23. Disconnect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
24. Disconnect the fuel hose routing clip from the transaxle stud and position the fuel hose aside.
25. Disconnect the 2 engine wiring harness electrical connectors. Detach the electrical connector from the LH valve cover.
26. Remove the oil level indicator.
27. Detach the wiring harness retainer from the RH valve cover stud bolt.
28. Remove the bolt and the ground wire from the engine front cover.
29. Remove the nut, the ground wire and the radio interference capacitor wire from the engine front cover stud.
30. Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers.
31. Remove the 4 nuts and the exhaust flexible pipe and Y-pipe as an assembly. Discard the nuts and the gasket.
32. Remove the 3 pin-type retainers, the 7 screws and the radiator splash shield.
33. Remove the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-292537) article.
34. Remove the 2 secondary latches from the transmission fluid cooler tubes.
35. Using the special tool, disconnect the transmission cooling tubes.
36. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
37. Remove and discard the engine oil filter.
38. Remove the power steering cooler bracket bolt from the RH side of the subframe.
39. Remove the 4 bolts and support the driveshaft with a length of mechanic's wire.
40. Remove and discard the RH front halfshaft nut.
41. Remove the 2 nuts and the roll restrictor heat shield.
42. Remove the engine roll restrictor-to-subframe through bolt.
43. Remove and discard the power steering pressure (PSP) tube-to-pump banjo bolt and the 2 seals.
44. Remove and discard the steering intermediate shaft bolt. Separate the steering intermediate shaft from the steering gear.
45. Remove and discard the cotter pins and tie-rod end nuts. Using the special tool, separate the tie-rod ends from the wheel knuckles.
46. Remove the 2 stabilizer link-to-lower control arm nuts and separate the stabilizer bar links from the lower control arms.
47. Remove the lower control arm-to-knuckle pinch bolts and separate the lower control arms from the knuckles.
48. Remove the 3 RH subframe-to-lower bumper nuts.
49. Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.
50. Position the special tool under the subframe assembly.
51. Remove the 2 nuts, 4 bolts and the subframe support brackets.
52. Remove the 2 front subframe nuts.
53. Remove the 2 middle subframe nuts.
54. Using the special tool, lower the subframe assembly from the vehicle.
55. If equipped, disconnect the oil cooler coolant hoses.
56. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
57. Using the special tool, separate the RH halfshaft from the hub.
58. Remove the 2 RH catalytic converter support bracket bolts.
59. Remove the bolt, the nut and the RH catalytic converter support bracket.
60. Remove the 2 stud bolts and the RH halfshaft/intermediate shaft assembly.
61. Remove the 2 RH halfshaft bearing support bracket bolts and the RH halfshaft/intermediate shaft assembly.
62. Install the special tools.
63. Remove the transaxle support insulator through bolt and nut.
64. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
65. Remove the nut, bolt and engine mount brace.
66. Remove the 4 engine mount nuts.
67. Remove the 3 bolts and the engine mount.
68. Lower the engine and transaxle assembly from the vehicle.
69. If equipped, detach the engine block heater wiring harness retainers and position the harness aside.
70. Disconnect the PCV hose from the PCV valve.
71. Disconnect the throttle body (TB) electrical connector.
72. Detach the wiring harness retainers from the upper intake manifold.
73. Remove the upper intake manifold support bracket bolt.
74. Remove the 6 bolts and the upper intake manifold in the following sequence. Discard the gaskets.
75. Disconnect the RH catalyst monitor electrical connector.
76. Disconnect the PSP switch electrical connector.
77. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
78. Disconnect the 3 RH coil-on-plug electrical connectors.
79. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
80. Disconnect the LH VCT solenoid electrical connector.
81. Disconnect the 3 LH coil-on-plug electrical connectors.
82. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
83. Remove the 6 bolts and the 6 coil-on-plugs.
84. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
85. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
86. Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged. Using the special tools, remove the seal(s).
87. Remove the 3 bolts and the power steering pump.
88. Remove the 3 bolts and the accessory drive belt tensioner.
89. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
90. Using the special tool, remove the crankshaft pulley.
91. Using the special tool, remove and discard the crankshaft front seal.
92. Remove the 2 bolts and the engine mount bracket.
93. Remove the 2 engine mount studs.
94. Remove the 3 bolts and the engine mount bracket.
95. Remove the 22 engine front cover bolts.
96. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
97. Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
98. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
99. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
100. Install the special tool onto the flats of the LH camshafts.
101. Install the special tool onto the flats of the RH camshafts.
102. Remove the 3 bolts and the RH VCT housing.
103. Remove the 3 bolts and the LH VCT housing.
104. Remove and discard the VCT housing seals.
105. Remove the 2 bolts and the primary timing chain tensioner.
106. Remove the primary timing chain tensioner arm.
107. Remove the 2 bolts and the lower LH primary timing chain guide.
108. Remove the primary timing chain.
109. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
110. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
111. Remove the special tool from the LH camshafts.
112. Verify the LH camshafts are in the neutral position.
113. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.
114. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
115. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
116. Remove the special tool from the RH camshafts.
117. Rotate the RH camshafts counterclockwise to the neutral position.
118. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.

Valve Tappets

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.

1. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For additional information, refer to «Camshaft»(ref-292564-S42481757072008080400000) .
2. Remove the valve tappets from the cylinder head.

Valve Spring, Retainer and Seal

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249

Scheme 52

Scheme 53

Scheme 54

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.

1. Remove the valve tappets from the cylinder being serviced. For additional information, refer to «Valve Tappets»(ref-292564-S40099729322008080400000) .
2. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke.
3. Pressurize the cylinder using compressed air.
4. Using the Valve Spring Compressors, remove the keys, retainer and spring.
5. Remove and discard the valve stem seal.

Cylinder Head - RH

Material

All vehicles

1. Remove the RH camshafts. For additional information, refer to «Camshaft»(ref-292564-S42481757072008080400000) .
2. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
3. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
4. Disconnect the RH camshaft position (CMP) sensor electrical connector.
5. Remove the bolt and the ground cable from the RH cylinder.
6. Disconnect the 6 fuel injector electrical connectors (3 shown).
7. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
8. Disconnect the LH catalyst monitor sensor electrical connector.
9. Remove the 2 LH catalytic converter bracket bolts.
10. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
11. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
12. Remove the 2 RH catalytic converter bracket bolts.
13. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
14. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
15. Remove the 3 bolts and the RH exhaust manifold heat shield.
16. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
17. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292524) article.
18. Remove and discard the 6 RH exhaust manifold studs.
19. Remove the 2 bolts and the RH primary timing chain guide.
20. Remove the 2 bolts and the RH secondary timing chain tensioner.
21. Remove the 2 bolts and the engine lifting eye.
22. Remove the bolt and the upper intake manifold bracket.
23. Remove the bolt and the RH CMP sensor.
24. Remove the 4 bolts and the fuel rail and injectors as an assembly.
25. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket and O-ring seal.
26. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
27. Disconnect and remove the CHT sensor jumper harness.
28. Remove the valve tappets from the cylinder head.
29. Remove and discard the M6 bolt.
30. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
31. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
32. Support the cylinder head on a bench with the head gasket side up.
33. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).

Cylinder Head - LH

Material

All vehicles

1. Remove the LH camshafts. For additional information, refer to «Camshaft»(ref-292564-S42481757072008080400000) .
2. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
3. Disconnect the 6 fuel injector electrical connectors (3 shown).
4. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
5. Disconnect the LH camshaft position (CMP) sensor electrical connector.
6. Disconnect the LH heated oxygen sensor (HO2S) electrical connector.
7. Disconnect the LH catalyst monitor sensor electrical connector.
8. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
9. Disconnect the A/C compressor electrical connector.
10. Remove the nut and disconnect the generator B+ cable.
11. Disconnect the generator electrical connector.
12. Detach the wiring harness retainer from the generator.
13. Disconnect the engine oil pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
14. Remove the nut, 2 bolts and the A/C compressor.
15. Remove the nut, bolt and the generator.
16. Remove the 2 LH catalytic converter bracket bolts.
17. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
18. Remove the 3 bolts and the LH exhaust manifold heat shield.
19. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
20. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292524) article.
21. Remove and discard the 6 LH exhaust manifold studs.
22. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
23. Remove the 2 RH catalytic converter bracket bolts.
24. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
25. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
27. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket and O-ring seal.
28. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
29. Remove the bolt and the LH CMP sensor.
30. Remove the 2 bolts and the upper LH primary timing chain guide.
31. Remove the 2 bolts and the LH secondary timing chain tensioner.
32. Remove the valve tappets from the cylinder head.
33. Remove and discard the M6 bolt.
34. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
35. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
36. Support the cylinder head on a bench with the head gasket side up.
37. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).

Oil Pan

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Handle 205-153 (T80T-4000-W) Remover, Oil Seal 303-409 (T92C-6700CH) Seal Remover 303-1247/1 Strap Wrench 303-D055 (D85L-6000-A)

Material

All vehicles

1. Remove the engine from the vehicle. For additional information, refer to «Engine»(ref-292564-S07214233642008080400000) .
2. Remove the 8 bolts and the flexplate.
3. Remove the crankshaft sensor ring.
4. Mount the engine on a suitable engine stand.
5. If equipped, remove the heat shield and disconnect the block heater electrical connector. Detach all of the engine block heater harness retainers and remove the harness.
6. Disconnect the PCV hose from the PCV valve.
7. Disconnect the throttle body (TB) electrical connector.
8. Detach the wiring harness retainers from the upper intake manifold.
9. Remove the upper intake manifold support bracket bolt.
10. Remove the 6 bolts and the upper intake manifold in the following sequence. Discard the gaskets.
11. Disconnect the power steering pressure (PSP) switch electrical connector.
12. Disconnect the RH catalyst monitor sensor electrical connector.
13. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
14. Disconnect the 3 RH coil-on-plug electrical connectors.
15. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
16. Disconnect the LH catalyst monitor sensor electrical connector.
17. Disconnect the LH VCT solenoid electrical connector.
18. Disconnect the 3 LH coil-on-plug electrical connectors.
19. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
20. Remove the A/C compressor nut and stud.
21. Remove the 3 bolts and the power steering pump.
22. Remove the 3 bolts and the accessory drive belt tensioner.
23. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
24. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
25. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
26. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
27. Remove the 6 bolts and the 6 coil-on-plugs.
28. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
29. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
30. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
31. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
32. Using the special tool, remove the crankshaft pulley.
33. Using the special tool, remove and discard the crankshaft front seal.
34. Remove the 2 bolts and the engine mount bracket.
35. Remove the 2 engine mount studs.
36. Remove the 3 bolts and the engine mount bracket.
37. Remove the 22 engine front cover bolts.
38. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
39. Remove the 16 oil pan bolts.
40. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released. Remove the oil pan.
41. Clean the engine front cover and oil pan using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the engine front cover and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
42. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Oil Pump Screen and Pickup Tube

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.

1. Remove the oil pan. For additional information, refer to «Oil Pan»(ref-292564-S27218140572008080400000) .
2. Remove the 3 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.

Crankshaft Rear Seal with Retainer Plate

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Material

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. This procedure is for removal of the crankshaft rear seal and retainer plate and requires removal of the oil pan. If only removing the crankshaft rear seal, refer to Crankshaft Rear Seal .

1. Remove the oil pan. For additional information, refer to «Oil Pan»(ref-292564-S27218140572008080400000) .
2. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
3. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
4. Remove the bolt and the CKP sensor.
5. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
6. Remove the 8 crankshaft rear seal retainer bolts.
7. Install the 2 M6 oil pan bolts (finger tight) into the 2 threaded holes in the crankshaft rear seal retainer. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released. Remove the crankshaft rear seal retainer.
8. Clean the crankshaft rear seal retainer plate using a 3M Roloc® Bristle Disk, (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
9. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Camshaft Alignment Tool 303-1248 Handle 205-153 (T80T-4000-W) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Oil Seal 303-409 (T92C-6700CH) Remover, Seal 303-1247/1 Slide Hammer 307-005 (T59L-100-B) Strap Wrench 303-D055 (D85L-6000-A)

Material

Note. For additional information, refer to the exploded view under the assembly procedure in this service information.

All vehicles

1. Remove the 8 bolts and the flexplate.
2. Remove the crankshaft sensor ring.
3. Using the special tools, remove and discard the rear crankshaft seal.
4. Mount the engine on a suitable engine stand.
5. If equipped, remove the heat shield and disconnect the block heater electrical connector. Detach all of the engine block heater harness retainers and remove the harness.
6. Disconnect the PCV hose from the PCV valve.
7. Disconnect the throttle body (TB) electrical connector.
8. Detach the wiring harness retainers from the upper intake manifold.
9. Remove the upper intake manifold support bracket bolt.
10. Remove the 6 bolts and the upper intake manifold in the following sequence. Discard the gaskets.
11. Disconnect the power steering pressure (PSP) switch electrical connector.
12. Disconnect the RH catalyst monitor sensor electrical connector.
13. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
14. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
15. Disconnect the 3 RH coil-on-plug electrical connectors.
16. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
17. Disconnect the RH camshaft position (CMP) sensor electrical connector.
18. Disconnect the knock sensor (KS) electrical connector.
19. Remove the bolt and the ground cable from the RH cylinder.
20. Disconnect the 6 fuel injector electrical connectors (3 shown).
21. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
22. Disconnect the LH CMP sensor electrical connector.
23. Disconnect the LH catalyst monitor sensor electrical connector.
24. Disconnect the LH HO2S electrical connector.
25. Disconnect the 3 LH coil-on-plug electrical connectors.
26. Disconnect the LH VCT solenoid electrical connector.
27. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
28. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
29. Remove the nut, the bolt and the heat shield.
30. Remove the wiring harness retainer stud bolt.
31. Remove the wiring harness grommet.
32. Disconnect the crankshaft position (CKP) sensor electrical connector.
33. Disconnect the A/C compressor electrical connector.
34. Remove the nut and disconnect the generator B+ cable.
35. Disconnect the generator electrical connector.
36. Detach the wiring harness retainer from the generator.
37. Disconnect the engine oil pressure (EOP) switch electrical connector and the wiring harness pin-type retainer. Remove the wiring harness from the engine.
38. Remove the nut, 2 bolts and the A/C compressor.
39. Remove the A/C compressor mounting stud from the oil pan.
40. Remove the nut, bolt and the generator.
41. Remove the 3 bolts and the power steering pump.
42. Remove the 3 bolts and the accessory drive belt tensioner.
43. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
44. Remove the 3 bolts and the LH exhaust manifold heat shield.
45. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
46. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292524) article.
47. Remove and discard the 6 LH exhaust manifold studs.
48. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
49. Remove the 3 bolts and the RH exhaust manifold heat shield.
50. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
51. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-292524) article.
52. Remove and discard the 6 RH exhaust manifold studs.
53. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
54. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
55. Remove the pin-type retainer and the cover.
56. Remove the 2 bolts and the engine lifting eye.
57. Remove the bolt and the upper intake manifold bracket.
58. Remove the bolt and the RH CMP sensor.
59. Remove the 2 bolts and the catalytic converter bracket.
60. Remove the 4 bolts and the fuel rail and injectors as an assembly.
61. Remove the 3 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket.
62. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
63. Disconnect and remove the CHT sensor jumper harness.
64. Remove the bolt and the LH CMP sensor.
65. Remove the bolt and the CKP sensor.
66. Remove the EOP switch.
67. If equipped, remove the 6 bolts and the oil cooler. Discard the oil cooler and the gaskets.
68. Remove the 2 bolts and the oil filter adapter. Discard the gasket and O-ring seal (on banjo bolt).
69. Remove the 6 bolts and the 6 coil-on-plugs.
70. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
71. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
72. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
73. Remove the crankshaft bolt and washer. Discard the bolt.
74. Using the special tool, remove the crankshaft pulley.
75. Using the special tool, remove and discard the crankshaft front seal.
76. Remove the 2 bolts and the engine mount bracket.
77. Remove the 2 engine mount studs.
78. Remove the 3 bolts and the engine mount bracket.
79. Remove the 22 engine front cover bolts.
80. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
81. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
82. Install the special tool onto the flats of the LH camshafts.
83. Install the special tool onto the flats of the RH camshafts.
84. Remove the 3 bolts and the RH VCT housing.
85. Remove the 3 bolts and the LH VCT housing.
86. Remove and discard the VCT housing seals.
87. Remove the 2 bolts and the primary timing chain tensioner.
88. Remove the primary timing chain tensioner arm.
89. Remove the 2 bolts and the lower LH primary timing chain guide.
90. Remove the primary timing chain.
91. Remove the crankshaft timing chain sprocket.
92. Remove the 2 bolts and the upper LH primary timing chain guide.
93. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
94. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
95. Remove the special tool from the LH camshafts.
96. Verify the LH camshafts are in the neutral position.
97. Remove the 2 bolts and the LH secondary timing chain tensioner.
98. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.
99. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
100. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
101. Remove the special tool from the RH camshafts.
102. Rotate the RH camshafts counterclockwise to the neutral position.
103. Remove the 2 bolts and the RH secondary timing chain tensioner.
104. Remove the 2 bolts and the RH primary timing chain guide.
105. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.
106. Remove the valve tappets from the cylinder heads.
107. Remove and discard the M6 bolt from each cylinder head.
108. Remove and discard the 8 bolts from each cylinder head. Remove the cylinder heads. Discard the cylinder head gaskets.
109. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
110. Support the cylinder heads on a bench with the head gasket side up.
111. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
112. Remove the coolant tube. Remove and discard the O-ring seals.
113. Remove the 2 bolts and the KS.
114. Remove the 8 bolts and the coolant pump.
115. Remove the 16 oil pan bolts.
116. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released. Remove the oil pan.
117. Remove the 3 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
118. Remove the 3 bolts and the oil pump.
119. Remove the 8 crankshaft rear seal retainer bolts.
120. Install the 2 M6 oil pan bolts (finger tight) into the 2 threaded holes in the crankshaft rear seal retainer. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released. Remove the crankshaft rear seal retainer.
121. Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M Roloc® Bristle Disk, (2 inch, white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm. Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
122. Clean the sealing surfaces of the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Cylinder Head

Special Tools Illustration Tool Name Tool Number 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)

Material

Scheme 55

Special Tools Illustration Tool Name Tool Number Alignment Pins 307-399 Camshaft Alignment Tool 303-1248 Handle 205-153 (T80T-4000-W) Installer, Crankshaft Front Seal 303-1251 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Seal 303-1247/2 Powertrain Lift 014-00765 Strap Wrench 303-D055 (D85L-6000-A)

Material

All camshafts

1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
2. Position the camshafts onto the LH cylinder head in the neutral position as shown.
3. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Position the camshafts onto the RH cylinder head in the neutral position as shown.
5. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
6. 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-292564-S39129138562008080400000) .
7. Rotate the LH camshafts to the top dead center position and install the special tool on the flats of the camshafts.
8. Assemble the LH variable camshaft timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
9. Position the LH secondary timing assembly onto the camshafts.
10. Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
11. Remove the lockpin from the LH secondary timing chain tensioner.
12. Rotate the RH camshafts to the top dead center position and install the special tool on the flats of the camshafts.
13. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
14. Position the RH secondary timing assembly onto the camshafts.
15. Install 2 new bolts and the original washer. Tighten in 4 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 10 Nm (89 lb-in). Stage 4: Tighten 90 degrees.
16. Remove the lockpin from the RH secondary timing chain tensioner.
17. Rotate the crankshaft clockwise 60 degrees to the top dead center position (crankshaft dowel pin at 11 o'clock).
18. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
19. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
20. Install the primary timing chain tensioner arm.
21. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lockpin.
22. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
23. As a post-check, verify correct alignment of all timing marks.
24. Install new VCT housing seals.
25. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
26. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
27. Install the special tools.
28. 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 3 engine mount bracket 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.
29. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
30. Remove the special tools (alignment pins).
31. Install the engine mount bracket and the 3 bolts.
32. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
33. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
34. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
35. Using the special tools, install a new crankshaft front seal.
36. Using the special tools, install the crankshaft pulley.
37. Using the special tool, 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.
38. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (8 lb-ft).
39. Install the power steering pump and the 3 bolts. Tighten to 24 Nm (18 lb-ft).
40. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
41. Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
42. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
43. Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
44. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
45. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
46. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
47. Connect the 3 LH coil-on-plug electrical connectors.
48. Connect the LH camshaft VCT solenoid electrical connector.
49. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
50. Connect the 3 RH coil-on-plug electrical connectors.
51. Connect the RH VCT solenoid electrical connector.
52. Connect the power steering pressure (PSP) switch electrical connector.
53. Connect the RH catalyst monitor sensor electrical connector.
54. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
55. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
56. Attach the wiring harness retainers to the upper intake manifold.
57. Connect the throttle body (TB) electrical connector.
58. Connect the PCV hose to the PCV valve.
59. If equipped, attach the engine block heater wiring harness retainers.
60. Raise the engine and transaxle assembly into the vehicle.
61. Install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
62. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
63. Install the engine mount brace, the nut and the bolt. Tighten to 20 Nm (15 lb-ft).
64. Install the transaxle support insulator bracket, the 3 nuts and the bolt. Tighten to 63 Nm (46 lb-ft).
65. Install the transaxle support insulator through bolt and nut. Tighten to 175 Nm (129 lb-ft).
66. Install a new PTU seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-292570) article.
67. Position the RH halfshaft/intermediate shaft assembly in the PTU and in the steering knuckle and install the 2 bolts. Tighten to 40 Nm (30 lb-ft).
68. Position the RH halfshaft/intermediate shaft assembly in the transaxle and in the steering knuckle and install the 2 stud bolts. Tighten to 55 Nm (41 lb-ft).
69. Install the converter support bracket and the 2 bolts.
70. Install the catalytic converter bracket bolt and the nut. Tighten the nut to 40 Nm (30 lb-ft). Tighten the bolt to 55 Nm (41 lb-ft).
71. Tighten the 2 RH catalytic converter support bracket bolts to 20 Nm (15 lb-ft).
72. Install the LH halfshaft into the transaxle.
73. If equipped, connect the oil cooler coolant hoses.
74. Using the special tool, raise the subframe into the installed position.
75. Install the 2 middle subframe nuts. Tighten to 133 Nm (98 lb-ft).
76. Install the 2 front subframe nuts. Tighten to 133 Nm (98 lb-ft).
77. Position the subframe support brackets in place and loosely install the 4 bolts.
78. Install the 2 rear subframe bracket nuts. Tighten to 133 Nm (98 lb-ft).
79. Tighten the 4 subframe support bracket bolts. Tighten to 90 Nm (66 lb-ft).
80. Position the lower bumper on the subframe and install the 3 LH nuts. Tighten to 9 Nm (80 lb-in).
81. Install the 3 RH lower bumper-to-subframe nuts. Tighten to 9 Nm (80 lb-in).
82. Install the ball joints in the steering knuckles and install the pinch bolts. Tighten to 55 Nm (41 lb-ft).
83. Position the stabilizer bar links in the lower control arms and install the nuts. Tighten to 90 Nm (66 lb-ft).
84. Install the tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install new cotter pins.
85. Install the intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
86. Using a new banjo bolt and 2 new seals, install the PSP tube. Tighten to 48 Nm (35 lb-ft).
87. Install the engine roll restrictor-to-subframe through bolt. Tighten to 103 Nm (76 lb-ft).
88. Install the roll restrictor heat shield and the 2 nuts. Tighten to 11 Nm (8 lb-ft).
89. Install a new RH front halfshaft nut. Tighten to 350 Nm (258 lb-ft).
90. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts. Tighten to 70 Nm (52 lb-ft).
91. Install the power steering cooler bracket bolt to the RH side of the subframe. Tighten to 9 Nm (80 lb-in).
92. Connect the power steering cooler hose.
93. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
94. Connect the 2 transmission fluid cooler tubes.
95. Install the 2 secondary latches onto the transmission fluid cooler tubes.
96. Install the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-292537) article.
97. Install the radiator splash shield, the 3 pin-type retainers and the 7 screws.
98. Using a new gasket, install the Y-pipe and exhaust flexible pipe assembly and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
99. Install the 2 exhaust hangers and tighten the exhaust clamp. Tighten to 40 Nm (30 lb-ft).
100. Install the ground wire, the radio interference capacitor wire and the nut to the engine front cover stud. Tighten to 10 Nm (89 lb-in).
101. Install the ground wire and bolt to the engine front cover. Tighten to 10 Nm (89 lb-in).
102. Attach the wiring harness retainer to the RH valve cover stud bolt.
103. Install the oil level indicator.
104. Connect the 2 engine wiring harness electrical connectors. Attach the electrical connector to the LH valve cover.
105. Connect the fuel hose routing clip to the transaxle stud.
106. Connect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
107. Connect the hose to the power steering reservoir.
108. Connect the A/C suction tube fitting. Install the safety clip onto the A/C fitting.
109. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut. Tighten to 8 Nm (71 lb-in).
110. If equipped, attach the engine block heater harness retainers from to the radiator support and the A/C suction tube.
111. Connect the transaxle control electrical connector.
112. Attach the control cable to the bracket. Connect the transaxle control cable to the control lever.
113. Attach the wiring harness retainer to the transaxle control cable bracket.
114. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
115. Connect the upper evaporative emissions (EVAP) tube quick connect coupling. to the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292568) article.
116. Connect the vacuum hose to the upper intake manifold.
117. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in). Attach the 2 wiring harness retainers to the cowl.
118. Connect the power feed to the battery terminal and install the nut. Tighten to 8 Nm (71 lb-in).
119. Connect the battery harness electrical connector.
120. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-292545) article.
121. Install the engine air cleaner and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-292569) article.
122. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
123. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-292530) article.
124. Fill the engine with clean engine oil.
125. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-292560) article.
126. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-292528) article.
127. Recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(ref-292527) article.

Material

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.

1. Install the valve tappets.
2. Depending on the valve tappets being serviced, install the LH and/or the RH camshafts. For additional information, refer to «Camshaft»(ref-292564-S27705605882008080400000) .

Special Tools Illustration Tool Name Tool Number 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)

Material

1. Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
2. Using the Valve Spring Compressors, install the valve spring, retainer and key.
3. Install the valve tappets. For additional information, refer to «Valve Tappets»(ref-292564-S17010526552008080400000) .

Material

All vehicles

1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
2. Install the bolt. Tighten to 10 Nm (89 lb-in).
3. Install the valve tappets.
4. Install and connect the cylinder head temperature (CHT) sensor jumper harness.
5. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
6. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
7. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
8. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
9. Install the RH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
10. Install the upper intake manifold bracket and the bolt. Tighten to 10 Nm (89 lb-in).
11. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
12. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
13. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
14. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
15. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
16. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
17. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
18. Using a new gasket, install the RH catalytic converter and 4 new nuts.
19. Install the 2 RH catalytic converter bracket bolts. Tighten the 4 catalytic converter nuts to 40 Nm (30 lb-ft). Tighten the 2 catalytic converter bracket bolts to 20 Nm (15 lb-ft).
20. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
21. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
22. Install the 2 LH catalytic converter bracket bolts. Tighten to 20 Nm (15 lb-ft).
23. Connect the LH catalyst monitor sensor electrical connector.
24. Connect the CHT sensor electrical connector.
25. Connect the 6 fuel injector electrical connectors (3 shown).
26. Install the ground cable and the bolt. Tighten to 10 Nm (89 lb-in).
27. Connect the RH CMP sensor electrical connector.
28. Connect the RH heated oxygen sensor (HO2S) electrical connector.
29. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
30. Install the RH camshafts. For additional information, refer to «Camshaft»(ref-292564-S27705605882008080400000) .

Material

All vehicles

1. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
2. Install the bolt. Tighten to 10 Nm (89 lb-in).
3. Install the valve tappets.
4. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
5. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
6. Install LH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
7. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
8. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
9. Install new fuel injector O-ring seals. Remove the retaining clips and separate the fuel injectors from the fuel rail. Remove and discard the O-ring seals. Install new O-ring seals and lubricate with clean engine oil. Install the fuel injectors and the retaining clips onto the fuel rail.
10. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
11. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
12. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
13. Install the 2 RH catalytic converter bracket bolts. Tighten the 4 catalytic converter nuts to 40 Nm (30 lb-ft). Tighten the 2 catalytic converter brackets to 20 Nm (15 lb-ft).
14. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
15. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
16. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten to 20 Nm (15 lb-ft).
17. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 14 Nm (10 lb-ft).
18. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
19. Install the 2 LH catalytic converter bracket bolts. Tighten to 20 Nm (15 lb-ft).
20. Install the generator, the bolt and the nut. Tighten to 47 Nm (35 lb-ft).
21. Install the A/C compressor, the nut and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
22. Connect the engine oil pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
23. Attach the wiring harness retainer to the generator.
24. Connect the generator electrical connector.
25. Connect the generator B+ cable and install the nut. Tighten to 6 Nm (53 lb-in).
26. Connect the A/C compressor electrical connector.
27. Install the wiring harness retainer bolt on the rear of the LH cylinder head. Tighten to 10 Nm (89 lb-in).
28. Connect the LH catalyst monitor sensor electrical connector.
29. Connect the LH HO2S electrical connector.
30. Connect the LH CMP sensor electrical connector.
31. Connect the CHT sensor electrical connector.
32. Connect the 6 fuel injector electrical connectors (3 shown).
33. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
34. Install the LH camshafts. For additional information, refer to «Camshaft»(ref-292564-S27705605882008080400000) .

Special Tools Illustration Tool Name Tool Number Alignment Pins 307-399 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Front Seal 303-1251 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A)

Material

All vehicles

1. Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the oil pan. 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.
2. Install the oil pan and bolts 10, 11, 13 and 14. Tighten the bolts in the sequence shown to 3 Nm (27 lb-in). Loosen the bolts 180 degrees.
3. Align the oil pan to the cylinder block and the A/C compressor. Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.
4. Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).
5. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown. Tighten the large bolts (1-14) to 20 Nm (15 lb-ft). Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
6. Install the A/C compressor mounting stud and nut. Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
7. Install the special tools.
8. 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 3 engine mount bracket 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.
9. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
10. Remove the special tools (alignment pins).
11. Install the engine mount bracket and the 3 bolts.
12. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages: Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft). Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
13. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
14. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
15. Using the special tools, install a new crankshaft front seal.
16. Using the special tools, install the crankshaft pulley.
17. Using the special tool, 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.
18. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
19. Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
20. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
21. Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
22. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
23. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
24. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
25. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
26. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
27. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
28. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (8 lb-ft).
29. Install the power steering pump and the 3 bolts. Tighten to 24 Nm (18 lb-ft).
30. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
31. Connect the 3 LH coil-on-plug electrical connectors.
32. Connect the LH camshaft VCT solenoid electrical connector.
33. Connect the LH catalyst monitor sensor electrical connector.
34. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
35. Connect the 3 RH coil-on-plug electrical connectors.
36. Connect the RH VCT solenoid electrical connector.
37. Connect the RH catalyst monitor sensor electrical connector.
38. Connect the power steering pressure (PSP) switch electrical connector.
39. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
40. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
41. Attach the wiring harness retainers to the upper intake manifold.
42. Connect the throttle body (TB) electrical connector.
43. Connect the PCV hose to the PCV valve.
44. If equipped, position the engine block heater harness on the engine and attach all of the harness retainers. Connect the engine block heater electrical connector and install the heat shield.
45. Using the special tools, remove the engine from the stand.
46. Install the crankshaft sensor ring.
47. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).
48. Install the engine in the vehicle. For additional information, refer to «Engine»(ref-292564-S18634828792008080400000) .

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.

1. 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).
2. Install the oil pan. For additional information, refer to «Oil Pan»(ref-292564-S16793089052008080400000) .

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Rear Main Seal 303-1250 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Material

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.

1. 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.
2. Install the rear seal retainer and the 8 bolts in the sequence shown. Tighten in the sequence shown to 10 Nm (89 lb-in).
3. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
4. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
5. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
6. Connect the CKP sensor electrical connector.
7. Using the Heavy Duty Floor Crane and Spreader Bar, install the engine onto the stand.
8. Install the oil pan. For additional information, refer to «Oil Pan»(ref-292564-S16793089052008080400000) .