Engine - 3.5L: Other Lincoln MKZ 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 .

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 assemblie(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 . For driveability concerns, refer to the Introduction - Gasoline Engines .

Valve Clearance Check

1. Remove the valve covers. For additional information, refer to «Valve Cover - LH»(ref-271130-S05040746582007110800000) and «Valve Cover - RH»(ref-271130-S35441640272007110800000) .
2. Use a feeler gauge to measure the clearance of each valve and record its location. A mid-range 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-271130-S25218971162007110800000) .

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

Scheme 34

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 35

Scheme 36

Scheme 37

Scheme 38

Material

Crankshaft Front Seal

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

Scheme 39

Scheme 40

Material

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Installer, Crankshaft Rear Seal 303-1250 Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B)

Scheme 41

Scheme 42

Scheme 43

Material

Oil Filter Adapter

Material

Scheme 44

Engine Oil Pressure (EOP) Switch

Material

Scheme 45

Exhaust Manifold - LH

Material

Scheme 46

Exhaust Manifold - RH

Material

Scheme 47

Engine Mount

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

Scheme 48

Scheme 49

Scheme 50

Engine Front Cover

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Adapter for 204-592 204-592/1 Handle 205-153 (T80T-4000-W) Powertrain Lift 014-00765 Remover, Halfshaft 205-243 Remover, Halfshaft 205-832 Remover, Oil Seal 303-409 (T92C-6700CH) Remover, Seal 303-1247/1 Separator, Ball Joint 205-592 Slide Hammer 100-001 303-D055 (D85L-6000-A) Strap Wrench Tie-Rod End Remover 211-105 Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

Material

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-271051) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-271127) .
3. Recover the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-271114) .
4. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE - 3.5L»(ref-271134) .
5. If equipped, remove the 6 screws and the underbody shield.
6. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.
7. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-271067) .
8. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L»(ref-271131) .
9. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
10. Disconnect the 2 engine wiring harness electrical connectors.
11. Detach the 2 wiring harness retainers from transmission mount and the battery tray bracket.
12. Remove the nut and disconnect the power feed wire from the battery terminal.
13. Remove the bolt and position aside the ground wire.
14. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
15. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
16. Disconnect the transaxle control cable from the control lever.
17. Remove the 3 nuts and position the transaxle control cable bracket aside.
18. Remove the bolt and position the ground wire aside.
19. If equipped, detach the engine block heater harness from the radiator support, power steering hose, A/C tube and the engine wiring harness.
20. Detach the coolant tube retainer clips from the A/C tube.
21. Remove the nut and disconnect the A/C tube from the condenser. Discard the O-ring seals.
22. Remove the 2 A/C tube bracket bolts.
23. Remove the A/C tube bracket bolt.
24. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
25. Detach the 2 wiring harness retainers.
26. Disconnect the 2 engine wiring harness electrical connectors.
27. Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring harness aside.
28. Remove the oil level indicator.
29. Disconnect the hose from the power steering reservoir. Detach the pin-type retainer from the engine mount brace.
30. Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the cowl.
31. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-271127) .
32. Remove the bolt and the ground wire from the engine mount brace.
33. Remove the 3 bolts and the engine mount brace.
34. Disconnect the powertrain control module (PCM) electrical connectors and pin-type retainers.
35. Remove the power steering pressure (PSP) hose bracket bolt.
36. Remove and discard the PSP banjo bolt and the 2 seals from the steering gear.
37. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
38. Remove the 2 nuts and the steering joint cover.
39. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
40. Remove the 4 screws and position the LH fender splash shield aside.
41. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
42. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
43. Disconnect the transaxle cooler hoses.
44. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
45. Remove and discard the engine oil filter.
46. Remove the 6 nuts and the Y-pipe assembly. Discard the gaskets and nuts.
47. Remove the 4 bolts (3 shown) and support the driveshaft with a length of mechanic's wire.
48. Remove the engine roll restrictor-to-subframe through bolt.
49. Remove the cotter pins and nuts from the tie-rod ends.
50. Using the special tool, separate the tie-rod ends from the steering knuckles.
51. Remove the nuts and separate the stabilizer bar links from the struts.
52. Remove the 4 lower ball joint nuts.
53. Using the special tools, separate the lower ball joints from the lower control arms.
54. Remove the through bolts from the lower control arms.
55. Position the special tool under the subframe assembly.
56. Remove the 4 subframe bracket-to-body bolts.
57. Remove the 2 subframe nuts and the 2 subframe brackets.
58. Remove the 2 front subframe nuts.
59. Using the special tool, lower the subframe assembly from the vehicle.
60. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
61. Remove the 2 RH halfshaft carrier bearing bolts. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
62. Remove the 2 RH catalytic converter bracket bolts.
63. Remove the 2 nuts and remove the RH catalytic converter bracket.
64. Remove the RH halfshaft carrier bearing bolt and the 2 stud bolts. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
65. Install the special tools.
66. Remove the transaxle mount through bolt.
67. Remove the transaxle mount bracket bolt and the 2 nuts.
68. Remove the 4 engine mount nuts.
69. Remove the nut, 2 bolts and the engine mount.
70. Lower the engine and transaxle assembly from the vehicle.
71. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
72. If equipped, detach the block heater wiring harness retainers from the power steering pressure (PSP) hose and the power steering reservoir hose.
73. Disconnect the positive crankcase ventilation (PCV) fitting electrical connector.
74. Disconnect the PCV hose from the PCV valve.
75. Disconnect the throttle body electrical connector.
76. Detach the wiring harness retainers from the upper intake manifold.
77. Remove the upper intake manifold support bracket bolt.
78. Remove the upper intake manifold support bracket bolt.
79. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
80. Disconnect the RH catalyst monitor electrical connector.
81. Disconnect the power steering pressure (PSP) switch electrical connector.
82. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
83. Disconnect the 3 RH coil-on-plug electrical connectors.
84. Disconnect the heated PCV valve electrical connector.
85. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
86. Disconnect the LH VCT solenoid electrical connector.
87. Disconnect the 3 LH coil-on-plug electrical connectors.
88. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
89. Remove the 6 bolts and the 6 coil-on-plugs.
90. Detach the PSP hose retainer from the engine lifting eye.
91. Remove the PSP hose bracket nut and position the PSP hose aside.
92. Remove the 2 nuts and the wiring harness retaining bracket.
93. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
94. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
95. Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged. Using the special tools, remove the seal(s).
96. Remove the 3 bolts and position the power steering pump aside.
97. Remove the 3 bolts and the accessory drive belt tensioner.
98. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
99. Using the special tool, remove the crankshaft pulley.
100. Using the special tool, remove and discard the crankshaft front seal.
101. Remove the 2 bolts and the engine mount bracket.
102. Remove the 2 engine mount studs.
103. Remove the 3 bolts and the engine mount bracket.
104. Remove the 22 engine front cover bolts.
105. 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.
106. 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.
107. Clean all engine sealing surfaces, including the cylinder heads, the oil pan and cylinder block. 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.

Timing Drive Components

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

Scheme 51

1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-271130-S08072091892007110800000) .
2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
3. Install the special tool onto the flats of the LH camshafts.
4. Install the special tool onto the flats of the RH camshafts.
5. Remove the 3 bolts and the RH VCT housing.
6. Remove the 3 bolts and the LH VCT housing.
7. Remove and discard the VCT housing seals.
8. Remove the 2 bolts and the primary timing chain tensioner.
9. Remove the primary timing chain tensioner arm.
10. Remove the 2 bolts and the lower LH primary timing chain guide.
11. Remove the primary timing chain.
12. Remove the crankshaft timing chain sprocket.
13. Remove the 2 bolts and the upper LH primary timing chain guide.
14. Compress the LH secondary timing chain tensioner and install a suitable lock pin to retain the tensioner in the collapsed position.
15. 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.
16. Remove the 2 bolts and the LH secondary timing chain tensioner.
17. Compress the RH secondary timing chain tensioner and install a suitable lock pin to retain the tensioner in the collapsed position.
18. 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.
19. Remove the 2 bolts and the RH secondary timing chain tensioner.
20. Remove the 2 bolts and the RH primary timing chain guide.

Camshaft

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

All camshafts

1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-271130-S08072091892007110800000) .
2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
3. Install the special tool onto the flats of the LH camshafts.
4. Install the special tool onto the flats of the RH camshafts.
5. Remove the 3 bolts and the RH VCT housing.
6. Remove the 3 bolts and the LH VCT housing.
7. Remove and discard the VCT housing seals.
8. Remove the 2 bolts and the primary timing chain tensioner.
9. Remove the primary timing chain tensioner arm.
10. Remove the 2 bolts and the lower LH primary timing chain guide.
11. Remove the primary timing chain.
12. Compress the LH secondary timing chain tensioner and install a suitable lock pin to retain the tensioner in the collapsed position.
13. 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.
14. Remove the special tool from the LH camshafts.
15. Verify the LH camshafts are in the neutral position.
16. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.
17. Compress the RH secondary timing chain tensioner and install a suitable lock pin to retain the tensioner in the collapsed position.
18. 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.
19. Remove the special tool from the RH camshafts.
20. Rotate the RH camshafts counterclockwise to the neutral position.
21. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.

Valve Tappets

1. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For additional information, refer to «Camshaft»(ref-271130-S39859323442007110800000) .
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

1. Remove the valve tappets from the cylinder being serviced. For additional information, refer to «Valve Tappets»(ref-271130-S25218971162007110800000) .
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 special tool, 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-271130-S39859323442007110800000) .
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. Remove the bolt and position aside the RH radio interference capacitor.
5. Disconnect the RH camshaft position (CMP) sensor electrical connector.
6. Remove the bolt and the power steering pressure (PSP) tube and bracket assembly.
7. Disconnect the 6 fuel injector electrical connectors (3 shown).
8. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
9. Disconnect the LH catalyst monitor sensor electrical connector.
10. Remove the 2 LH catalytic converter bracket bolts.
11. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
12. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
13. Remove the 2 RH catalytic converter bracket bolts.
14. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
15. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
16. Remove the 3 bolts and the RH exhaust manifold heat shield.
17. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
18. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075) .
19. Remove and discard the 6 RH exhaust manifold studs.
20. Remove the 2 bolts and the RH primary timing chain guide.
21. Remove the 2 bolts and the RH secondary timing chain tensioner.
22. Remove the 2 bolts and the engine lifting eye.
23. Remove the bolt and the upper intake manifold bracket.
24. Remove the bolt and the upper intake manifold bracket.
25. Remove the bolt and the RH CMP sensor.
26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
27. Remove the 2 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. Disconnect and remove the CHT sensor jumper harness.
30. Remove the valve tappets from the cylinder head.
31. Remove and discard the M6 bolt.
32. Remove and discard the 8 bolts from the cylinder head. Remove the cylinder head. Discard the cylinder head gasket.
33. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block. 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.
34. Support the cylinder head on a bench with the head gasket side up.
35. 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-271130-S39859323442007110800000) .
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 A/C compressor electrical connector.
4. Remove the nut and disconnect the generator B+ cable.
5. Disconnect the generator electrical connector.
6. Detach the wiring harness retainer from the generator.
7. Remove the nut, bolt and the generator.
8. Detach the wiring harness pin-type retainer.
9. Disconnect the 6 fuel injector electrical connectors (3 shown).
10. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
11. Remove the bolt and position aside the LH radio interference capacitor.
12. Disconnect the LH CMP sensor electrical connector.
13. Disconnect the LH heated oxygen sensor (HO2S) electrical connector.
14. Disconnect the LH catalyst monitor sensor electrical connector.
15. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
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-271075) .
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 2 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. 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 Handle 205-153 (T80T-4000-W) Seal Remover 303-1247/1 3-Jaw Puller 303-D121 Remover, Oil Seal 303-409 (T92C-6700CH) 303-D055 (D85L-6000-A) Strap Wrench

Material

All vehicles

1. Remove the engine from the vehicle. For additional information, refer to «Engine»(ref-271130-S27186205512007110800000) .
2. Remove the 8 bolts and the flywheel.
3. Remove the crankshaft sensor ring.
4. Mount the engine on a suitable engine stand.
5. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
6. If equipped, remove the heat shield and disconnect the block heater electrical connector.
7. If equipped, detach the block heater wiring harness retainer from the power steering reservoir hose and the power steering pressure (PSP) hose. Remove the block heater wiring harness from the engine.
8. Disconnect the positive crankcase ventilation (PCV) fitting electrical connector.
9. Disconnect the PCV hose from the PCV valve.
10. Disconnect the throttle body electrical connector.
11. Detach the wiring harness retainers from the upper intake manifold.
12. Remove the upper intake manifold support bracket bolt.
13. Remove the upper intake manifold support bracket bolt.
14. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
15. Disconnect the power steering pressure (PSP) switch electrical connector.
16. Disconnect the RH catalyst monitor sensor electrical connector.
17. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
18. Disconnect the 3 RH coil-on-plug electrical connectors.
19. Disconnect the heated PCV valve electrical connector.
20. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
21. Disconnect the LH catalyst monitor sensor electrical connector.
22. Disconnect the LH VCT solenoid electrical connector.
23. Disconnect the 3 LH coil-on-plug electrical connectors.
24. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
25. Remove the A/C compressor nut and stud.
26. Detach the PSP hose retainer from the engine lifting eye.
27. Remove the PSP hose bracket nut.
28. Remove the 3 bolts and position the power steering pump aside.
29. Remove the 3 bolts and the accessory drive belt tensioner.
30. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
31. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
32. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
33. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
34. Remove the 6 bolts and the 6 coil-on-plugs.
35. Remove the 2 nuts and the wiring harness retaining bracket.
36. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
37. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
38. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
39. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
40. Using the special tool, remove the crankshaft pulley.
41. Using the special tool, remove and discard the crankshaft front seal.
42. Remove the 2 bolts and the engine mount bracket.
43. Remove the 2 engine mount studs.
44. Remove the 3 bolts and the engine mount bracket.
45. Remove the 22 engine front cover bolts.
46. 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.
47. Remove the 16 oil pan bolts.
48. 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.
49. 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.
50. Clean all engine sealing surfaces of the cylinder block. 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

1. Remove the oil pan. For additional information, refer to «Oil Pan»(ref-271130-S21450359662007110800000) .
2. Remove the 3 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.

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

1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(ref-271130-S08072091892007110800000) .
2. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing (VCT) assemblies as shown.
3. Install the special tool onto the flats of the LH camshafts.
4. Install the special tool onto the flats of the RH camshafts.
5. Remove the 3 bolts and the RH VCT housing.
6. Remove the 3 bolts and the LH VCT housing.
7. Remove and discard the VCT housing seals.
8. Remove the 2 bolts and the primary timing chain tensioner.
9. Remove the primary timing chain tensioner arm.
10. Remove the 2 bolts and the lower LH primary timing chain guide.
11. Remove the primary timing chain.
12. Remove the crankshaft timing chain sprocket.
13. Remove the 2 oil pump screen and pickup tube bolts.
14. Remove the 3 oil pump bolts. Rotate the oil pump clockwise and separate the oil pump from the oil pump screen and pickup tube. Remove the oil pump. Discard the oil pump screen and pickup tube 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. 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-271130-S21450359662007110800000) .
2. Using the special tools, 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 special tools, 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) 303-D055 (D85L-6000-A) Strap Wrench

Material

Note. For additional information, refer to the exploded view under the ASSEMBLY .

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, detach the block heater wiring harness retainer from the upper intake manifold.
6. If equipped, remove the heat shield and disconnect the block heater electrical connector.
7. If equipped, detach the block heater wiring harness retainer from the power steering reservoir hose and the power steering pressure (PSP) hose. Remove the block heater wiring harness from the engine.
8. Disconnect the positive crankcase ventilation (PCV) fitting electrical connector.
9. Disconnect the PCV hose from the PCV valve.
10. Disconnect the throttle body electrical connector.
11. Detach the wiring harness retainers from the upper intake manifold.
12. Remove the upper intake manifold support bracket bolt.
13. Remove the upper intake manifold support bracket bolt.
14. Remove the 6 bolts and the upper intake manifold. Discard the gaskets.
15. Disconnect the power steering pressure (PSP) switch electrical connector.
16. Disconnect the RH catalyst monitor sensor electrical connector.
17. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
18. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
19. Disconnect the 3 RH coil-on-plug electrical connectors.
20. Disconnect the heated PCV valve electrical connector.
21. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
22. Remove the bolt and position aside the RH radio interference capacitor.
23. Disconnect the RH camshaft position (CMP) sensor electrical connector.
24. Disconnect the knock sensor (KS) electrical connector.
25. Disconnect the 6 fuel injector electrical connectors (3 shown).
26. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
27. Remove the bolt and position aside the LH radio interference capacitor.
28. Disconnect the LH CMP sensor electrical connector.
29. Disconnect the LH catalyst monitor sensor electrical connector.
30. Disconnect the LH HO2S electrical connector.
31. Disconnect the 3 LH coil-on-plug electrical connectors.
32. Disconnect the LH VCT solenoid electrical connector.
33. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
34. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
35. Remove the nut, the bolt and the heat shield.
36. Remove the wiring harness retainer stud bolt.
37. Remove the wiring harness grommet.
38. Disconnect the crankshaft position (CKP) sensor electrical connector.
39. Disconnect the A/C compressor electrical connector.
40. Remove the nut and disconnect the generator B+ cable.
41. Disconnect the generator electrical connector.
42. Detach the wiring harness retainer from the generator.
43. Disconnect the engine oil pressure (EOP) switch electrical connector and the wiring harness pin-type retainer. Remove the wiring harness from the engine.
44. Remove the bolt and the A/C manifold. Discard the O-ring seals.
45. Remove the nut, 2 bolts and the A/C compressor.
46. Remove the A/C compressor mounting stud from the oil pan.
47. Remove the bolt, nut and the generator.
48. Detach the PSP hose retainer from the engine lifting eye.
49. Remove the PSP hose bracket nut.
50. Remove the PSP tube bracket bolt from the RH cylinder head.
51. Remove the 3 bolts and the power steering pump.
52. Remove the 3 bolts and the accessory drive belt tensioner.
53. Remove the 4 nuts (3 shown) and the LH catalytic converter. Discard the nuts and the gasket.
54. Remove the 3 bolts and the LH exhaust manifold heat shield.
55. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
56. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075) .
57. Remove and discard the 6 LH exhaust manifold studs.
58. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
59. Remove the 3 bolts and the RH exhaust manifold heat shield.
60. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
61. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-271075) .
62. Remove and discard the 6 RH exhaust manifold studs.
63. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
64. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
65. Remove the pin-type retainer and the cover.
66. Remove the 2 bolts and the engine lifting eye.
67. Remove the bolt and the upper intake manifold bracket.
68. Remove the bolt and the upper intake manifold bracket.
69. Remove the bolt and the RH CMP sensor.
70. Remove the 2 bolts and the catalytic converter bracket.
71. Remove the 4 bolts and the fuel rail and injectors as an assembly.
72. Remove the 2 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket.
73. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
74. Disconnect and remove the CHT sensor jumper harness.
75. Remove the bolt and the LH CMP sensor.
76. Remove the bolt and the CKP sensor.
77. Remove the EOP switch.
78. Remove the 2 bolts and the oil filter adapter. Discard the gasket and the O-ring seal.
79. Remove the 6 bolts and the 6 coil-on-plugs.
80. Remove the 2 nuts and the wiring harness retaining bracket.
81. Remove the 11 stud bolts and the LH valve cover. Discard the gasket.
82. Remove the bolt, the 10 stud bolts and the RH valve cover. Discard the gasket.
83. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the special tools, remove the seal(s).
84. Remove the crankshaft bolt and washer. Discard the bolt.
85. Using the special tool, remove the crankshaft pulley.
86. Using the special tool, remove and discard the crankshaft front seal.
87. Remove the 2 bolts and the engine mount bracket.
88. Remove the 2 engine mount studs.
89. Remove the 3 bolts and the engine mount bracket.
90. Remove the 22 engine front cover bolts.
91. 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.
92. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
93. Install the special tool onto the flats of the LH camshafts.
94. Install the special tool onto the flats of the RH camshafts.
95. Remove the 3 bolts and the RH VCT housing.
96. Remove the 3 bolts and the LH VCT housing.
97. Remove and discard the VCT housing seals.
98. Remove the 2 bolts and the primary timing chain tensioner.
99. Remove the primary timing chain tensioner arm.
100. Remove the 2 bolts and the lower LH primary timing chain guide.
101. Remove the primary timing chain.
102. Remove the crankshaft timing chain sprocket.
103. Remove the 2 bolts and the upper LH primary timing chain guide.
104. Compress the LH secondary timing chain tensioner and install a suitable lock pin to retain the tensioner in the collapsed position.
105. 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.
106. Remove the special tool from the LH camshafts.
107. Verify the LH camshafts are in the neutral position.
108. Remove the 2 bolts and the LH secondary timing chain tensioner.
109. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.
110. Compress the RH secondary timing chain tensioner and install a suitable lock pin to retain the tensioner in the collapsed position.
111. 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.
112. Remove the special tool from the RH camshafts.
113. Rotate the RH camshafts counterclockwise to the neutral position.
114. Remove the 2 bolts and the RH secondary timing chain tensioner.
115. Remove the 2 bolts and the RH primary timing chain guide.
116. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.
117. Remove the valve tappets from the cylinder heads.
118. Remove and discard the M6 bolt from each cylinder head.
119. Remove and discard the 8 bolts from each cylinder head. Remove the cylinder heads. Discard the cylinder head gaskets.
120. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block. 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.
121. Support the cylinder heads on a bench with the head gasket side up.
122. 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).
123. Remove the coolant tube. Remove and discard the O-ring seals.
124. Remove the 2 bolts and the knock sensor (KS).
125. Remove the 8 bolts and the coolant pump.
126. Remove the 16 oil pan bolts.
127. 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.
128. Remove the 3 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
129. Remove the 3 bolts and the oil pump.
130. Remove the 8 crankshaft rear seal retainer bolts.
131. 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.
132. Clean the engine front cover, oil pan and 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 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.
133. Clean all engine sealing surfaces of the cylinder block. 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 engine front cover 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 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 303-D055 (D85L-6000-A) Strap Wrench Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

Material

All vehicles

1. Install the special tools.
2. 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.
3. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in).
4. Remove the special tools (alignment pins).
5. Install the engine mount bracket and the 3 bolts.
6. 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).
7. Install the 2 engine mount studs. Tighten to 18 Nm (13 lb-ft).
8. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
9. Using the special tools, install a new crankshaft front seal.
10. Using the special tools, install the crankshaft pulley.
11. 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.
12. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 10 Nm (89 lb-in).
13. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
14. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
15. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
16. 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).
17. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
18. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
19. Install the wiring harness retaining bracket and the 2 nuts. Tighten to 9 Nm (80 lb-in).
20. Install the power steering pressure (PSP) hose bracket and nut. Tighten to 9 Nm (80 lb-in).
21. Attach the PSP hose retainer to the engine lifting eye.
22. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
23. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
24. Connect the 3 LH coil-on-plug electrical connectors.
25. Connect the LH camshaft VCT solenoid electrical connector.
26. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
27. Connect the heated positive crankcase ventilation (PCV) valve electrical connector.
28. Connect the 3 RH coil-on-plug electrical connectors.
29. Connect the RH VCT solenoid electrical connector.
30. Connect the PSP switch electrical connector.
31. Connect the RH catalyst monitor sensor electrical connector.
32. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
33. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
34. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
35. Attach the wiring harness retainers to the upper intake manifold.
36. Connect the throttle body electrical connector.
37. Connect the PCV hose to the PCV valve.
38. Connect the PCV fitting electrical connector.
39. If equipped, attach the block heater wiring harness retainer to the PSP tube and the power steering reservoir hose.
40. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
41. Raise the engine and transaxle assembly into the vehicle.
42. Install the engine mount, the nut and the 2 bolts. Tighten the bolts to 55 Nm (41 lb-ft). Tighten the nut to 63 Nm (46 lb-ft).
43. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
44. Install the transaxle mount bracket, bolt and the 2 nuts. Tighten to 80 Nm (59 lb-ft).
45. Install the transaxle mount through bolt and nut. Tighten to 90 Nm (66 lb-ft).
46. Position the RH halfshaft in the transaxle and install the bolt and the 2 stud bolts. Tighten to 55 Nm (41 lb-ft).
47. Install the RH catalytic converter support bracket and the 2 bolts.
48. Install the 2 catalytic converter support bracket nuts. Tighten to 40 Nm (30 lb-ft). Tighten the 2 catalytic converter support bracket bolts to 20 Nm (15 lb-ft).
49. Install a new PTU seal. For additional information, refer to «ENGINE IGNITION - 3.0L (4V)»(ref-271128) .
50. Position the RH halfshaft in the transaxle and install the 2 bolts. Tighten to 23 Nm (17 lb-ft).
51. Install the LH halfshaft into the transaxle.
52. Using the special tool, raise the subframe into the installed position.
53. Install the 2 front subframe nuts. Tighten to 150 Nm (111 lb-ft).
54. Position the subframe brackets and install the 4 bolts finger-tight.
55. Install the 2 rear subframe nuts. Tighten to 150 Nm (111 lb-ft).
56. Tighten the 2 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
57. Install the through bolts into the lower control arms. Tighten to 103 Nm (76 lb-ft).
58. Install the 4 lower ball joint nuts. Tighten to 200 Nm (148 lb-ft).
59. Install the stabilizer bar links and nuts to the struts.
60. Install the tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install new cotter pins.
61. Install the engine roll restrictor-to-subframe through bolt. Tighten to 90 Nm (66 lb-ft).
62. Line up the index marks on the rear driveshaft to the index marks on the power transfer unit (PTU) flange made during removal and install the 4 bolts (3 shown). Tighten to 70 Nm (52 lb-ft).
63. Using new gaskets, install the Y-pipe assembly and the 6 new nuts. Tighten to 40 Nm (30 lb-ft).
64. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
65. Connect the 2 transmission fluid cooler hoses.
66. Connect the power steering cooler tube.
67. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body. From under the vehicle, verify that the seal is correctly installed on the steering gear and the retaining clips are fully engaged into the body.
68. If equipped, install the underbody shield and the 6 screws.
69. Install the LH splash shield and the 6 pin-type retainers (4 shown).
70. Position the LH fender splash shield and install the 4 screws.
71. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 23 Nm (17 lb-ft).
72. Install the steering joint cover and the 2 nuts.
73. Using a new banjo bolt and 2 new seals, install the PSP tube onto the steering gear. Tighten to 37 Nm (27 lb-ft).
74. Install the PSP tube bracket and nut. Tighten to 10 Nm (89 lb-in).
75. Connect the powertrain control module (PCM) connectors and pin-type retainers.
76. Install the engine mount brace and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
77. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
78. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-271127) .
79. Attach the power steering reservoir onto the cowl.
80. Connect the hose to the power steering reservoir. Attach the pin-type retainer to the engine mount brace.
81. Install the oil level indicator.
82. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
83. Connect the 2 engine wiring harness electrical connectors.
84. Attach the 2 wiring harness retainers.
85. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 8 Nm (71 lb-in).
86. Install the A/C tube bracket bolt. Tighten to 8 Nm (71 lb-in).
87. Install the 2 A/C tube bracket bolts. Tighten to 10 Nm (89 lb-in).
88. Using a new O-ring seal, connect the A/C tube to the condenser and install the nut. Tighten to 8 Nm (71 lb-in).
89. Attach the coolant tube retainer clips to the A/C tube.
90. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
91. Install the ground wire and bolt. Tighten to 12 Nm (9 lb-ft).
92. Position the transaxle control cable bracket in place and install the 3 nuts. Tighten to 12 Nm (9 lb-ft).
93. Connect the transaxle control cable to the control lever.
94. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
95. Connect the vacuum hose and the evaporative emissions (EVAP) tube to the upper intake manifold.
96. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
97. Connect the power feed to the battery terminal and install the nut. Tighten to 6 Nm (53 lb-in).
98. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
99. Connect the 2 engine wiring harness electrical connectors.
100. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-271102) .
101. Install the engine air cleaner and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L»(ref-271131) .
102. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-271067) .
103. Install the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE - 3.5L»(ref-271134) .
104. Fill the engine with clean engine oil.
105. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-271067) .
106. Fill the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-271082) .
107. Check the transaxle fluid and add fluid if necessary. For additional information, refer to the Transmission Fluid Drain and Refill procedure in «AUTOMATIC TRANSAXLE/TRANSMISSION - 6 SPEED»(ref-271076) .
108. Recharge the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-271114) .

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

1. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
2. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Assemble the RH variable camshaft timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
4. Position the RH secondary timing assembly onto the camshafts.
5. 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.
6. Remove the lock pin from the RH secondary timing chain tensioner.
7. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Assemble the LH 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 lock pin from the LH secondary timing chain tensioner.
12. Install the crankshaft timing chain sprocket.
13. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
14. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
15. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
16. Install the primary timing chain tensioner arm.
17. 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 lock pin.
18. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lock pin.
19. As a post-check, verify correct alignment of all timing marks.
20. Install new VCT housing seals.
21. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
22. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
23. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-271130-S37551235362007110800000) .

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

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-271130-S09960145402007110800000) .
7. Rotate the LH camshafts to the top dead center (TDC) 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 lock pin from the LH secondary timing chain tensioner.
12. Rotate the RH camshafts to the TDC 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 lock pin from the RH secondary timing chain tensioner.
17. Rotate the crankshaft clockwise 60 degrees to the TDC 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 lock pin.
22. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lock pin.
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 engine front cover. For additional information, refer to «Engine Front Cover»(ref-271130-S37551235362007110800000) .

Material

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-271130-S16484836072007110800000) .

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 special tool, install a new valve stem seal.
2. Using the special tools, install the valve spring, retainer and key.
3. Install the valve tappets. For additional information, refer to «Valve Tappets»(ref-271130-S01733522942007110800000) .

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 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 2 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 upper intake manifold bracket and the bolt. Tighten to 10 Nm (89 lb-in).
12. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
13. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
14. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
15. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
16. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in the sequence shown to 20 Nm (15 lb-ft).
17. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
18. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
19. Using a new gasket, install the RH catalytic converter and 4 new nuts.
20. 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).
21. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
22. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
23. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
24. Install the 2 LH catalytic converter bracket bolts. Tighten to 20 Nm (15 lb-ft).
25. Connect the LH catalyst monitor sensor electrical connector.
26. Connect the CHT sensor electrical connector.
27. Connect the 6 fuel injector electrical connectors (3 shown).
28. Install the power steering pressure (PSP) tube bracket and bolt. Tighten to 10 Nm (89 lb-in).
29. Connect the RH CMP sensor electrical connector.
30. Install the RH radio interference capacitor and the bolt. Tighten to 10 Nm (89 lb-in).
31. Connect the RH HO2S electrical connector.
32. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
33. Install the RH camshafts. For additional information, refer to «Camshaft»(ref-271130-S16484836072007110800000) .

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 2 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.
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. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
15. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
16. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
17. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in the sequence shown to 20 Nm (15 lb-ft).
18. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
19. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
20. Install the 2 LH catalytic converter bracket bolts. Tighten to 20 Nm (15 lb-ft).
21. Install the wiring harness retainer bolt on the rear of the LH cylinder head. Tighten to 10 Nm (89 lb-in).
22. Connect the LH catalyst monitor sensor electrical connector.
23. Connect the LH heated oxygen sensor (HO2S) electrical connector.
24. Connect the LH CMP sensor electrical connector.
25. Install the LH radio interference capacitor and the bolt. Tighten to 10 Nm (89 lb-in).
26. Connect the CHT sensor electrical connector.
27. Connect the 6 fuel injector electrical connectors (3 shown).
28. Attach the wiring harness pin-type retainer.
29. Install the generator, the bolt and the nut. Tighten to 48 Nm (35 lb-ft).
30. Attach the wiring harness retainer to the generator.
31. Connect the generator electrical connector.
32. Connect the generator B+ cable and install the nut. Tighten to 6 Nm (53 lb-in).
33. Connect the A/C compressor electrical connector.
34. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
35. Install the LH camshafts. For additional information, refer to «Camshaft»(ref-271130-S16484836072007110800000) .

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 303-D055 (D85L-6000-A) Strap Wrench

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 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 24 Nm (18 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 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 an 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 an 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 wiring harness retaining bracket and the 2 nuts. Tighten to 9 Nm (80 lb-in).
24. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in).
25. Install the LH cylinder block drain plug. Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
26. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
27. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft).
28. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown). Tighten to 40 Nm (30 lb-ft).
29. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 10 Nm (89 lb-in).
30. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
31. Install the power steering pressure (PSP) hose bracket and nut. Tighten to 9 Nm (80 lb-in).
32. Attach the PSP hose retainer to the engine lifting eye.
33. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
34. Connect the LH camshaft VCT solenoid electrical connector.
35. Connect the 3 LH coil-on-plug electrical connectors.
36. Connect the LH catalyst monitor sensor electrical connector.
37. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
38. Connect the heated positive crankcase ventilation (PCV) valve electrical connector.
39. Connect the 3 RH coil-on-plug electrical connectors.
40. Connect the RH VCT solenoid electrical connector.
41. Connect the RH catalyst monitor sensor electrical connector.
42. Connect the power steering pressure (PSP) switch electrical connector.
43. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
44. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
45. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
46. Attach the wiring harness retainers to the upper intake manifold.
47. Connect the throttle body electrical connector.
48. Connect the PCV hose to the PCV valve.
49. Connect the PCV fitting electrical connector.
50. If equipped, position the block heater wiring harness onto the engine. Attach the block heater wiring harness retainer to the power steering reservoir hose and the PSP hose.
51. If equipped, connect the block heater electrical connector and install the heat shield.
52. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
53. Using the special tools, remove the engine from the stand.
54. Install the crankshaft sensor ring.
55. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).
56. Install the engine in the vehicle. For additional information, refer to «Engine»(ref-271130-S03554929562007110800000) .

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-271130-S24393993842007110800000) .

1. Position the oil pump onto the crankshaft and rotate counterclockwise to position the pump onto the oil pump screen and pickup tube. Install the 3 bolts and tighten to 10 Nm (89 lb-in).
2. Install the 2 oil pump screen and pickup tube bolts. Tighten to 10 Nm (89 lb-in).
3. Install the crankshaft timing chain sprocket.
4. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
5. Install the LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
6. Install the primary timing chain tensioner arm.
7. 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 lock pin.
8. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lock pin.
9. As a post-check, verify correct alignment of all timing marks.
10. Install new VCT housing seals.
11. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
12. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
13. Install the engine front cover. For additional information, refer to «Engine Front Cover»(ref-271130-S37551235362007110800000) .

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

Material

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 special tool onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
4. Using the special tools, 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 special tools, install the engine onto the stand.
8. Install the oil pan. For additional information, refer to «Oil Pan»(ref-271130-S24393993842007110800000) .