Engine Mechanical - 3.5L: Other Lincoln MKZ I рестайлинг

Engine Code Information Label

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

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ITEM DESCRIPTION TABLE

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Exhaust Emission Control System

Operation and required maintenance of the exhaust emission control devices used on this engine is covered in the INTRODUCTION -- GASOLINE MODELS .

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

For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION . For driveability concerns, refer to INTRODUCTION - GASOLINE MODELS .

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1. Remove the valve covers. For additional information, refer to «Removal»(ref-355916-S33431262092010013000000) (Valve Cover - LH) and «Removal»(ref-355916-S34414492692010013000000) (Valve Cover - RH).
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: 0.360-0.460 mm (0.0142-0.0181 in) NOTE: Engine must be at room temperature before measuring. The valve clearance must be measured with the camshaft at base circle. The engine will have to be rotated with the crankshaft pulley bolt to bring each valve to base circle.
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. NOTE: The number on the valve tappet reflects the thickness of the valve tappet. For example, a tappet with the number 3.310 has the thickness of 3.31 mm (0.13 in). 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-355916-S31437014412010013000000) .

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ITEM DESCRIPTION TABLE

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Material

ITEM SPECIFICATION TABLE

Valve Cover - LH (View 1 of 2)

Note. Early build shown in illustration, late build similar.

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ITEM DESCRIPTION TABLE

Valve Cover - LH (View 2 of 2)

Note. Early build shown in illustration, late build similar.

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ITEM SPECIFICATION TABLE

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ITEM DESCRIPTION TABLE

Valve Cover - RH (View 3 of 3)

Note. Early build shown in illustration, late build similar.

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ITEM SPECIFICATION TABLE

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355922) .
2. Remove the accessory drive belt and the power steering belt. For additional information, refer to «REMOVAL»(ref-355937-S42663157132010013000000) .
3. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
4. Using the 3 Jaw Puller, remove the crankshaft pulley.

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1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the crankshaft pulley. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
3. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Install the accessory drive belt and the power steering belt. For additional information, refer to «INSTALLATION»(ref-355937-S33935887892010013000000) .

ITEM SPECIFICATION TABLE

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355922) .
2. Remove the crankshaft pulley. For additional information, refer to «Removal»(ref-355916-S17418685322010013000000) .
3. Using the Oil Seal Remover, remove and discard the crankshaft front seal. Clean all sealing surfaces with metal surface prep.

Scheme 269

1. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
2. Install the crankshaft pulley. For additional information, refer to «Installation»(ref-355916-S37346063432010013000000) .

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ITEM DESCRIPTION TABLE

1. For additional information, refer to the appropriate procedure(s).

ITEM SPECIFICATION TABLE

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355922) .
2. Remove the flexplate. For additional information, refer to «Removal and Installation»(ref-355916-S19430639652010013000000) .
3. Remove the crankshaft sensor ring.
4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the crankshaft rear seal. Clean all sealing surfaces with metal surface prep.

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1. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
2. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
3. Install the crankshaft sensor ring.
4. Install the flexplate. For additional information, refer to «Removal and Installation»(ref-355916-S19430639652010013000000) .
5. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

ITEM SPECIFICATION TABLE

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ITEM DESCRIPTION TABLE

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1. Remove the LH catalytic converter. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355930-S39838825692010013000000) .
2. Remove the LH Heated Oxygen Sensor (HO2S). For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355978-S40222232422010013000000) .
3. Remove the 3 bolts and the LH exhaust manifold heat shield.
4. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and gasket.
5. Clean and inspect the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-355929-S39305709122010013000000) .
6. Remove and discard the 6 LH exhaust manifold studs.
7. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Scheme 279

1. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
2. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
3. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
4. Install the LH HO2S . For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355978-S40222232422010013000000) .
5. Install the LH catalytic converter. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355930-S39838825692010013000000) .

ITEM SPECIFICATION TABLE

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ITEM DESCRIPTION TABLE

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1. Remove the RH catalytic converter. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355930-S02170201032010013000000) .
2. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
3. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and gasket.
4. Clean and inspect the RH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-355929-S39305709122010013000000) .
5. Remove and discard the 6 RH exhaust manifold studs.
6. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Scheme 282

1. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
2. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
3. Connect the RH HO2S electrical connector.
4. Install the RH catalytic converter. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355930-S02170201032010013000000) .

ITEM SPECIFICATION TABLE

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.

Scheme 283

1. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For additional information, refer to «Removal and Installation»(ref-355916-S04720268482010060800000) .
2. Remove the valve tappets from the cylinder head. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

ITEM SPECIFICATION TABLE

ITEM SPECIFICATION

ITEM SPECIFICATION TABLE

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.

Scheme 284

1. Remove the oil pan. For additional information, refer to «Removal and Installation»(ref-355916-S06514381152010060800000) .
2. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.

ITEM SPECIFICATION TABLE

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 Removal .

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1. Remove the oil pan. For additional information, refer to «Removal and Installation»(ref-355916-S06514381152010060800000) .
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. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
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. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

ITEM SPECIFICATION TABLE

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

Note. For additional information, refer to ASSEMBLY .

All vehicles

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1. Remove the 8 bolts and the flexplate.
2. Remove the crankshaft sensor ring.
3. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
4. Mount the engine on a suitable engine stand. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
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 PCV hose from the PCV valve.
9. Disconnect the Throttle Body (TB) electrical connector.
10. Detach the wiring harness retainers from the upper intake manifold.
11. Remove the upper intake manifold support bracket bolt.
12. Remove the 6 bolts and the upper intake manifold. Discard the gaskets. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
13. Disconnect the PSP switch electrical connector. Front Wheel Drive (FWD) vehicles
14. Disconnect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector. All vehicles
15. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
16. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
17. Disconnect the 3 RH coil-on-plug electrical connectors.
18. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
19. Disconnect the coolant bypass hose from the thermostat housing.
20. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
21. Disconnect the Knock Sensor (KS) electrical connector.
22. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
23. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
24. Disconnect the LH CMP sensor electrical connector.
25. Disconnect the LH CMS sensor electrical connector.
26. Disconnect the LH HO2S electrical connector.
27. Disconnect the 3 LH coil-on-plug electrical connectors.
28. Disconnect the LH VCT solenoid electrical connector.
29. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
30. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
31. Remove the nut, the bolt and the heat shield.
32. Remove the wiring harness retainer stud bolt.
33. Remove the wiring harness grommet.
34. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
35. Disconnect the A/C compressor electrical connector.
36. Remove the nut and disconnect the generator B+ cable.
37. Disconnect the generator electrical connector.
38. Detach the wiring harness retainer from the generator.
39. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer. Remove the wiring harness from the engine.
40. Remove the bolt and the A/C manifold. Discard the O-ring seals.
41. Remove the nut, 2 bolts and the A/C compressor.
42. Remove the A/C compressor mounting stud from the oil pan.
43. Remove the bolt, nut and the generator.
44. Detach the PSP hose retainer from the engine lifting eye.
45. Remove the PSP hose bracket nut.
46. Remove the PSP tube bracket bolt from the RH cylinder head.
47. Remove the 3 bolts and the power steering pump.
48. Remove the 3 bolts and the accessory drive belt tensioner.
49. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter. Discard the nuts and the gasket.
50. Remove the 3 bolts and the LH exhaust manifold heat shield.
51. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
52. Clean and inspect the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-355929-S39305709122010013000000) .
53. Remove and discard the 6 LH exhaust manifold studs. FWD vehicles
54. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket. All vehicles
55. Remove the 3 bolts and the RH exhaust manifold heat shield.
56. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
57. Clean and inspect the RH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-355929-S39305709122010013000000) .
58. Remove and discard the 6 RH exhaust manifold studs.
59. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
60. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
61. Remove the pin-type retainer and the cover.
62. Remove the 2 bolts and the engine lifting eye.
63. Remove the bolt and the upper intake manifold support bracket.
64. Remove the bolt and the RH CMP sensor. All-Wheel Drive (AWD) vehicles
65. Remove the 2 bolts and the catalytic converter bracket. All vehicles
66. Remove the 4 bolts and the fuel rail and injectors as an assembly.
67. Remove the 2 thermostat housing-to-lower intake manifold bolts. Remove the thermostat housing and discard the gasket.
68. Remove the 10 bolts and the lower intake manifold. Discard the gaskets. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
69. Disconnect and remove the CHT sensor jumper harness.
70. Remove the bolt and the LH CMP sensor.
71. Remove the bolt and the CKP sensor.
72. Remove the EOP switch. Early build vehicles
73. Remove the 2 bolts and the oil filter adapter. Discard the gasket and the O-ring seal. Late build vehicles
74. Remove the 3 bolts and the oil filter adapter. Discard the gasket. All vehicles
75. Remove the 6 bolts and the 6 coil-on-plugs. NOTE: LH shown in illustration, RH similar.
76. Remove the 2 nuts and the wiring harness retaining bracket. Early build vehicles
77. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
78. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket. Late build vehicles
79. Loosen the 9 stud bolts and remove the LH valve cover. Discard the gasket.
80. Loosen the 9 stud bolts and remove the RH valve cover. Discard the gasket. All vehicles
81. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s). NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.
82. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
83. Using the 3 Jaw Puller, remove the crankshaft pulley.
84. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
85. Remove the 2 bolts and the engine mount bracket.
86. Remove the 2 engine mount studs. NOTE: Only use hand tools to remove the studs.
87. Remove the 3 bolts and the engine mount bracket.
88. Remove the 22 engine front cover bolts.
89. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover in the following sequence. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover. Engines equipped with early build RH timing chain guides
90. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. Engines equipped with late build/replacement RH timing chain guides
91. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration. All vehicles
92. Install the Camshaft Holding Tool onto the flats of the LH camshafts. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
93. Install the Camshaft Holding Tool onto the flats of the RH camshafts. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
94. Remove the 3 bolts and the RH VCT housing.
95. Remove the 3 bolts and the LH VCT housing.
96. Remove the 2 bolts and the primary timing chain tensioner.
97. Remove the primary timing chain tensioner arm.
98. Remove the 2 bolts and the lower LH primary timing chain guide.
99. Remove the primary timing chain.
100. Remove the crankshaft timing chain sprocket.
101. Remove the 2 bolts and the upper LH primary timing chain guide.
102. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
103. 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. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
104. Remove the Camshaft Holding Tool from the LH camshafts. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
105. Verify the LH camshafts are in the neutral position. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
106. Remove the 2 bolts and the LH secondary timing chain tensioner.
107. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
108. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
109. 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. NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
110. Remove the Camshaft Holding Tool from the RH camshafts.
111. Rotate the RH camshafts counterclockwise to the neutral position. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
112. Remove the 2 bolts and the RH secondary timing chain tensioner. Engines equipped with early build RH timing chain guides
113. Remove the 2 bolts and the RH primary timing chain guide. Engines equipped with late build/replacement RH timing chain guides
114. Remove the 2 bolts and the RH primary timing chain guide. All vehicles
115. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
116. Remove the valve tappets from the cylinder heads. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. NOTE: LH shown in illustration, RH similar.
117. Remove and discard the M6 bolt from each cylinder head. NOTE: LH shown in illustration, RH similar.
118. Remove and discard the 8 bolts from each cylinder head. Remove the cylinder heads. Discard the cylinder head gaskets. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. NOTE: LH shown in illustration, RH similar.
119. 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. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
120. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «CYLINDER HEAD DISTORTION»(ref-355929-S34550017702010013000000) and «CYLINDER BLOCK DISTORTION»(ref-355929-S07771196582010013000000) .
121. Remove the coolant inlet tube. Remove and discard the O-ring seals.
122. Remove the 2 bolts and the Knock Sensor (KS).
123. Remove the 8 bolts and the coolant pump.
124. Remove the 16 oil pan bolts.
125. Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan in the following sequence. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released. Remove the oil pan.
126. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
127. Remove the 3 bolts and the oil pump.
128. Remove the 8 crankshaft rear seal retainer bolts.
129. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer in the following sequence. 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.
130. 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. NOTE: Only use a 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
131. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
132. Remove the bolts in the sequence shown in illustration below. Remove the main bearing cap support brace. Discard the bolts. NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
133. Remove the connecting rod cap bolts and cap. NOTE: The connecting rod cap bolts are torque to yield. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement. NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.
134. Remove the piston/rod assembly from the engine block. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
135. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
136. Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration below. Discard the bolts. NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
137. Remove the 4 main bearing caps. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly. NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
138. Remove the crankshaft. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
139. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead. NOTE: Inside shown in illustration, outside similar.
140. Remove the 4 crankshaft main bearings from the cylinder block. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
141. Remove the 4 crankshaft main bearings from the main bearing caps. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
142. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-355929) .
143. Clean all engine 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 engine front cover locating dowel pins are seated correctly in the cylinder block. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure. NOTE: Do not use wire brushes, power abrasive discs or 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

ITEM SPECIFICATION TABLE

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ITEM DESCRIPTION TABLE

ITEM SPECIFICATION TABLE

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ITEM DESCRIPTION TABLE

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1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin. Discard the 2 piston pin retainer clips.
3. Separate the piston from the connecting rod. NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block. NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod for reassembly.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «PISTON INSPECTION»(ref-355929-S25930069802010013000000) and «CONNECTING ROD CLEANING»(ref-355929-S34909167292010013000000) .

Scheme 345

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

ITEM SPECIFICATION TABLE

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ITEM DESCRIPTION TABLE

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ITEM DESCRIPTION TABLE

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ITEM DESCRIPTION TABLE

Engine Front

Note. Early build engine shown in illustration, late build similar.

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ITEM DESCRIPTION TABLE

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ITEM DESCRIPTION TABLE

Note. During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Early build vehicle (built before July 6, 2009) cooling systems are filled with Motorcraft® Premium Gold Engine Coolant. Late build vehicle (built on or after July 6, 2009) cooling systems are filled with Motorcraft® Specialty Green Engine Coolant. Mixing coolant types degrades the corrosion protection of the coolant. Do not mix coolant types. Failure to follow these instructions may result in engine or cooling system damage.

Note. Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

Note. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

All vehicles

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1. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block face. The first letter after the first asterisk makes up the code for main No. 1 and the next letter for main No. 2. The first letter after the second asterisk makes up the code for main No. 3 and the last letter for main No. 4. NOTE: This procedure is for selecting bearings using a new crankshaft.
2. Using the table below, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column. If the block code is *BM*QS* and the crankshaft code is *OL*PO*, Main No. 1 should be built with grade 1 bearings, as determined by the intersection of the B block column and the O crankshaft row on the table. Mains No. 2, No. 3 and No. 4 should all be grade 2.
3. Using the original connecting rod cap bolts, install the connecting rod caps and bolts. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Tighten the bolts in 3 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Tighten an additional 90 degrees.
4. Measure the connecting rod large end bore in 2 directions. Remove the bolts and the rod cap. Discard the connecting rod cap bolts.
5. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
6. Using the table below, select the correct connecting rod bearings for each crankshaft connecting rod journal.
7. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
8. Install the crankshaft onto the upper main bearings. NOTE: Do not install the upper thrust bearings until the crankshaft is installed. NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.
9. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
10. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
11. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.
12. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
13. Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
14. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
15. Loosen the No. 4 main bearing cap bolts.
16. Tighten the main bearing bolts in the sequence shown in illustration below in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 60 Nm (44 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees. NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.
17. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in illustration below in 2 stages. Stage 1: Tighten fasteners 1 through 8 to 45 Nm (33 lb-ft). Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
19. Prepare the connecting rod and cap. Insert the new bolts in the rod cap. Insert the upper and lower rod bearings into the rod and cap. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
20. Before installing the pistons into the cylinder block, verify proper ring gap location. Center line of the piston parallel to the wrist pin bore Upper compression ring gap location Upper oil control segment ring gap location Lower oil control segment ring gap location Expander ring and lower compression ring gap location
21. Using the Piston Ring Compressor, install the piston and connecting rod assemblies. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown in illustration. NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil. NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to «PISTON»(ref-355916-S30033577462010013000000) . NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block. NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.
22. Seat the connecting rod on the crankshaft journal.
23. Install the connecting rod cap and bolts. Tighten the bolts in 3 stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Tighten an additional 90 degrees. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation.
24. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
25. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in illustration in 2 steps. Stage 1: Tighten fasteners to 20 Nm (177 lb-in). Stage 2: Tighten fasteners an additional 180 degrees.
26. 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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.
27. Install the rear seal retainer and the 8 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in).
28. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
29. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
30. Install the A/C compressor and the 2 bolts. Tighten to 25 Nm (18 lb-ft). NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.
31. 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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.
32. Install the oil pan and bolts 10, 11, 13 and 14. Tighten the bolts in the sequence shown in illustration below to 3 Nm (27 lb-in). Loosen the bolts 180 degrees. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.
33. 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 in illustration below.
34. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration below, to 3 Nm (27 lb-in).
35. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown in illustration. 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).
36. 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).
37. Install the coolant pump and the 8 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in).
38. Install the Knock Sensor (KS) and the 2 bolts. Tighten to 20 Nm (177 lb-in).
39. Using new O-ring seals, install the coolant inlet tube. NOTE: Apply clean engine coolant to the O-ring seals prior to installation.
40. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
41. Install the new M6 bolt. Tighten to 10 Nm (89 lb-in).
42. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration below in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
43. Install the new M6 bolt. Tighten to 10 Nm (89 lb-in).
44. Position the crankshaft dowel pin in the 9 o'clock position. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.
45. Install the valve tappets. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation. NOTE: LH shown in illustration, RH similar.
46. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration. NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur. NOTE: Coat the camshafts with clean engine oil prior to installation.
47. Install the 8 camshaft caps and the 16 bolts. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
48. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration. NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur. NOTE: Coat the camshafts with clean engine oil prior to installation.
49. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
50. 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-355916-S30079479932010013000000) . NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur. NOTE: Use a camshaft sprocket bolt to turn the camshafts. Engines equipped with early build RH timing chain guides
51. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). Engines equipped with late build/replacement RH timing chain guides
52. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). All vehicles
53. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
54. Rotate the RH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
55. 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.
56. Position the RH secondary timing assembly onto the camshafts.
57. 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.
58. Remove the lockpin from the RH secondary timing chain tensioner.
59. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in).
60. Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
61. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
62. Position the LH secondary timing assembly onto the camshafts.
63. 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.
64. Remove the lockpin from the LH secondary timing chain tensioner.
65. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
66. Install the crankshaft timing chain sprocket.
67. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
68. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
69. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
70. Install the primary timing chain tensioner arm.
71. 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.
72. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
73. As a post-check, verify correct alignment of all timing marks.
74. Inspect the VCT housing seals for damage and replace as necessary.
75. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
76. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
77. Install the Alignment Pins.
78. 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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
79. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in). NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
80. Remove the Alignment Pins.
81. Install the engine mount bracket and the 3 bolts. NOTE: Do not tighten the bolts at this time.
82. 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 illustration 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 (133 lb-in). 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). NOTE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
83. Install the engine mount studs in the following sequence. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material. Clean all the thread sealer from the engine mount studs (old and new studs). Apply new Threadlock and Sealer to the engine mount stud threads. Install the 2 engine mount studs. Tighten to 20 Nm (177 lb-in). NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.
84. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
85. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
86. Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the crankshaft pulley. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
87. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 (lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
88. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. NOTE: Spark plug tube seal installation shown in illustration, VCT solenoid seal installation similar.
89. 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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Early build vehicles
90. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). Late build vehicles
91. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
92. 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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Early build vehicles
93. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Late build vehicles
94. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). All vehicles
95. Install the wiring harness retaining bracket and the 2 nuts. Tighten to 4 Nm (35 lb-in).
96. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in). NOTE: LH shown in illustration, RH similar. Late build vehicles
97. Using a new gasket, install the oil filter adapter and 3 bolts. Tighten to 10 Nm (89 lb-in). Early build vehicles
98. Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts. Tighten the large bolt to 57 Nm (42 lb-ft). Tighten the small bolt to 10 Nm (89 lb-in). All vehicles
99. Install the EOP switch. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads. Tighten to 18 Nm (159 lb-in).
100. Install the Crankshaft Position (CKP) sensor and install the bolt. Tighten to 10 Nm (89 lb-in).
101. Install LH Camshaft Position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
102. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
103. Using new gaskets, install the lower intake manifold and the 10 bolts. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in).
104. Using a new gasket, install the thermostat housing and the 2 bolts. Tighten to 10 Nm (89 lb-in).
105. 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. NOTE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: The upper and lower O-ring seals are not interchangeable.
106. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in). All-Wheel Drive (AWD) vehicles
107. Install the catalytic converter bracket and the 2 bolts. Tighten to 40 Nm (30 lb-ft). All vehicles
108. Install the RH CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
109. Install the engine lifting eye and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
110. Install the cover and the pin-type retainer.
111. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
112. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft).
113. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
114. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration below: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak. Front Wheel Drive (FWD) vehicles
115. Using a new gasket, install the RH catalytic converter and the 4 new nuts. Tighten to 40 Nm (30 lb-ft). All vehicles
116. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
117. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration below: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
118. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
119. Using a new gasket, install the LH catalytic converter and the 4 new nuts (3 shown in illustration). Tighten to 40 Nm (30 lb-ft).
120. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
121. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
122. Install the Power Steering Pressure (PSP) tube bracket and bolt to the RH cylinder head. Tighten to 10 Nm (89 lb-in).
123. Install the PSP hose bracket nut. Tighten to 9 Nm (80 lb-in).
124. Attach the PSP hose retainer to the engine lifting eye.
125. Install the generator, the nut and the bolt. Tighten to 48 Nm (35 lb-ft).
126. Using new O-ring seals, install the A/C manifold and the bolt. Tighten to 25 Nm (18 lb-ft).
127. Position the wiring harness onto the engine.
128. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
129. Attach the wiring harness retainer to the generator.
130. Connect the generator electrical connector.
131. Connect the generator B+ cable and install the nut. Tighten to 12 Nm (106 lb-in).
132. Connect the A/C compressor electrical connector.
133. Connect the CKP sensor electrical connector.
134. Install the wiring harness grommet.
135. Install the wiring harness retainer stud bolt. Tighten to 10 Nm (89 lb-in).
136. Install the heat shield, the nut and the bolt. Tighten to 10 Nm (89 lb-in).
137. Install the wiring harness retainer bolt on the rear of the LH cylinder head. Tighten to 10 Nm (89 lb-in).
138. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
139. Connect the LH camshaft VCT solenoid electrical connector.
140. Connect the 3 LH coil-on-plug electrical connectors.
141. Connect the LH HO2S electrical connector.
142. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.
143. Connect the LH CMP sensor electrical connector.
144. Connect the CHT sensor electrical connector.
145. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
146. Connect the KS electrical connector.
147. Connect the RH CMP sensor electrical connector.
148. Connect the coolant bypass hose to the thermostat housing.
149. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
150. Connect the 3 RH coil-on-plug electrical connectors.
151. Connect the RH VCT solenoid electrical connector. FWD vehicles
152. Connect the RH CMS electrical connector. All vehicles
153. Connect the PSP switch electrical connector.
154. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
155. Install the upper intake manifold support bracket and the 2 bolts (one shown in illustration). Tighten to 10 Nm (89 lb-in).
156. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
157. Connect the RH HO2S electrical connector.
158. Attach the wiring harness retainers to the upper intake manifold.
159. Connect the Throttle Body (TB) electrical connector.
160. Connect the PCV hose to the PCV valve.
161. 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.
162. If equipped, connect the block heater electrical connector and install the heat shield.
163. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
164. Install the Engine Lift Eye on the LH cylinder head.
165. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
166. Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
167. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
168. Install the crankshaft sensor ring.
169. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).

ITEM SPECIFICATION TABLE

All vehicles

Scheme 429

Scheme 430

Scheme 431

Scheme 432

Scheme 433

Scheme 434

Scheme 435

Scheme 436

Scheme 437

Scheme 438

Scheme 439

Scheme 440

Scheme 441

Scheme 442

Scheme 443

Scheme 444

Scheme 445

1. Align the transaxle to the engine.
2. Install the 4 transaxle-to-engine bolts and the transaxle-to-engine stud bolt. Tighten to 48 Nm (35 lb-ft).
3. Install the 2 engine-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
4. Using the Heavy Duty Floor Crane and the Spreader Bar, position the engine and transaxle onto the lift table.
5. Install the Powertrain Lift and Universal Adapter Brackets. NOTE: Position a block of wood under the transaxle.
6. Install the starter and the 2 bolts. Tighten to 26 Nm (19 lb-ft).
7. Attach the starter wire terminals and install the 2 nuts. Tighten to 12 Nm (106 lb-in). Tighten to 5 Nm (44 lb-in). Position the starter terminal boot over the starter terminal.
8. Connect the Transmission Control Module (TCM) electrical connector.
9. Install the ground wire and bolt. Tighten to 12 Nm (106 lb-in).
10. Connect the wiring harness fasteners to the transaxle-to-engine stud bolt and the starter.
11. Raise the engine and transaxle assembly into the vehicle.
12. 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).
13. Install the 2 engine mount spacers and the 4 engine mount nuts. Tighten in the sequence shown in illustration below to 70 Nm (52 lb-ft).
14. Install the 2 transaxle support insulator bracket nuts and the bolt. Tighten to 80 Nm (59 lb-ft).
15. Install the transaxle support insulator through bolt and nut. Tighten to 90 Nm (66 lb-ft). All-Wheel Drive (AWD) vehicles
16. Using a small screwdriver, remove the compression seal and discard. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is moved from the vehicle.
17. Using a soft face hammer, install the new compression seal.
18. Position the PTU in place and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
19. Position the PTU support bracket in place and install the 5 bolts. Tighten to 70 Nm (52 lb-ft).
20. Using a new gasket, install the RH catalytic converter and 4 new nuts. NOTE: Do not tighten the 4 catalytic converter nuts at this time.
21. Install the 2 catalytic converter-to-bracket bolts. Tighten the 4 catalytic converter nuts to 40 Nm (30 lb-ft). Tighten the 2 catalytic converter-to-bracket bolts to 20 Nm (177 lb-in).
22. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector. Front Wheel Drive (FWD) vehicles
23. Install the RH catalytic converter support bracket and the 2 bolts. NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
24. 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 (177 lb-in). All vehicles
25. Using the Powertrain Lift, raise the subframe into the installed position.
26. Install the 2 front subframe nuts. Tighten to 150 Nm (111 lb-ft). NOTE: LH shown in illustration, RH similar.
27. Position the subframe brackets and install the 4 bolts finger-tight. NOTE: LH shown in illustration, RH similar.
28. Install the 2 rear subframe nuts. Tighten to 150 Nm (111 lb-ft). NOTE: LH shown in illustration, RH similar.
29. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft). NOTE: LH shown in illustration, RH similar.
30. Install the stabilizer bar links and nuts to the struts. Tighten to 40 Nm (30 lb-ft). NOTE: LH shown in illustration, RH similar.
31. Install the tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). Install new cotter pins. NOTE: LH shown in illustration, RH similar.
32. Install the engine roll restrictor-to-subframe through bolt. Tighten to 90 Nm (66 lb-ft). AWD vehicles
33. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts. Tighten to 70 Nm (52 lb-ft). All vehicles
34. Install 4 new torque converter nuts. Tighten to 36 Nm (27 lb-ft).
35. Install the inspection cover and the 2 fasteners.
36. Install the 4 oil pan-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
37. Using new gaskets, install the Y-pipe assembly and 6 new nuts. Tighten to 40 Nm (30 lb-ft).
38. Install a new engine oil filter. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
39. Connect the 2 transmission fluid cooler hoses.
40. Connect the power steering cooler tube.
41. 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 properly installed on the steering gear and the retaining clips are fully engaged into the body.
42. If equipped, install the underbody shield and the 6 screws.
43. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
44. Position the LH fender splash shield and install the 4 screws.
45. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 25 Nm (18 lb-ft). NOTE: Align the index marks made during removal.
46. Install the steering joint cover and the 2 nuts.
47. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube onto the steering gear. Tighten to 37 Nm (27 lb-ft).
48. Install the PSP tube bracket and bolt. Tighten to 10 Nm (89 lb-in).
49. Connect the PCM electrical connectors and pin-type retainers.
50. Install the engine mount brace and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
51. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
52. Connect the fuel supply tube from the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-355987) .
53. Attach the power steering reservoir onto the cowl.
54. Connect the hose to the power steering reservoir. Attach the pin-type retainer to the engine mount brace.
55. Install the oil level indicator.
56. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
57. Connect the 2 engine wiring harness electrical connectors.
58. Attach the 2 wiring harness retainers.
59. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 8 Nm (71 lb-in).
60. Install the A/C tube bracket bolt. Tighten to 8 Nm (71 lb-in).
61. Install the 2 A/C tube bracket bolts. Tighten to 10 Nm (89 lb-in).
62. 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).
63. Attach the coolant tube retainer clips to the A/C tube.
64. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
65. Install the ground wire and bolt. Tighten to 12 Nm (106 lb-in).
66. Position the transaxle control cable bracket in place and install the 3 nuts. Tighten to 12 Nm (106 lb-in).
67. Connect the transaxle control cable to the control lever.
68. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
69. Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold.
70. Install the ground wire and the bolt. Tighten to 12 Nm (106 lb-in).
71. Install the 2 battery cables to the positive battery cable and the 2 nuts. Tighten to 9 Nm (80 lb-in).
72. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
73. Connect the 2 engine wiring harness electrical connectors.
74. Install the battery tray. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355968-S25610670162010013000000) .
75. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355993-S28735189342010013000000) .
76. Install the degas bottle. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355972-S07928583072010013000000) .
77. Install the LH halfshaft and the intermediate shaft. For additional information, refer to «INSTALLATION»(ref-355956-S02551388902010042300000) .
78. Install the accessory drive belt and the power steering belt. For additional information, refer to «INSTALLATION»(ref-355937-S33935887892010013000000) .
79. Fill the engine with clean engine oil.
80. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-355972-S37681702192010013000000) .
81. Fill the power steering system. For additional information, refer to «POWER STEERING SYSTEM FILLING»(ref-355933-S06606262842010013000000) .
82. Check the transaxle fluid and add fluid if necessary. For additional information, refer to the «TRANSMISSION FLUID DRAIN AND REFILL»(ref-355918-S24459945602010013000000) .
83. Recharge the A/C system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-355932-S05895534102010013000000) .
84. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions

ITEM SPECIFICATION TABLE

All vehicles

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. Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

Scheme 457

Scheme 458

Scheme 459

Scheme 460

Scheme 461

1. Install the Alignment Pins.
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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
3. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in). NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
4. Remove the Alignment Pins.
5. Install the engine mount bracket and the 3 bolts. NOTE: Do not tighten the bolts at this time.
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 illustration 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 (133 lb-in). 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). NOTE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
7. Install the engine mount studs in the following sequence. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material. Clean all the thread sealer from the engine mount studs (old and new studs). Apply new Threadlock and Sealer to the engine mount stud threads. Install the 2 engine mount studs. Tighten to 20 Nm (177 lb-in). NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.
8. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
9. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
10. Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the crankshaft pulley. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
11. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
12. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
13. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
14. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. NOTE: Spark plug tube seal installation shown in illustration, Variable Camshaft Timing (VCT) solenoid seal installation similar.
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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Early build vehicles
16. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). Late build vehicles
17. Using a new gasket, install the RH valve cover, bolt and tighten the 9 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). All vehicles
18. 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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Early build vehicles
19. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). Late build vehicles
20. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). All vehicles
21. Install the wiring harness retaining bracket and the 2 nuts. Tighten to 4 Nm (35 lb-in).
22. Install the Power Steering Pressure (PSP) hose bracket and nut. Tighten to 9 Nm (80 lb-in).
23. Attach the PSP hose retainer to the engine lifting eye.
24. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in). NOTE: LH shown in illustration, RH similar.
25. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
26. Connect the 3 LH coil-on-plug electrical connectors.
27. Connect the LH camshaft VCT solenoid electrical connector.
28. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
29. Connect the 3 RH coil-on-plug electrical connectors.
30. Connect the RH VCT solenoid electrical connector.
31. Connect the PSP switch electrical connector.
32. Connect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.
33. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
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 (TB) electrical connector.
37. Connect the PCV hose to the PCV valve.
38. If equipped, attach the block heater wiring harness retainer to the PSP tube and the power steering reservoir hose.
39. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
40. Raise the engine and transaxle assembly into the vehicle.
41. 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).
42. Install the 2 engine mount spacers and the 4 engine mount nuts. Tighten in the sequence shown in illustration below to 70 Nm (52 lb-ft).
43. Install the transaxle support insulator bracket, bolt and the 2 nuts. Tighten to 80 Nm (59 lb-ft).
44. Install the transaxle support insulator through bolt and nut. Tighten to 90 Nm (66 lb-ft). Front Wheel Drive (FWD) vehicles
45. Install the RH catalytic converter support bracket and the 2 bolts. NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
46. 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 (177 lb-in). All-Wheel Drive (AWD) vehicles
47. Install a new PTU seal. For additional information, refer to «POWER TRANSFER UNIT (PTU)»(ref-355953) . NOTE: A new Power Transfer Unit (PTU) seal must be installed whenever the intermediate shaft is removed. All vehicles
48. Using the Powertrain Lift, raise the subframe into the installed position.
49. Install the 2 front subframe nuts. Tighten to 150 Nm (111 lb-ft). NOTE: LH shown in illustration, RH similar.
50. Position the subframe brackets and install the 4 bolts finger-tight. NOTE: LH shown in illustration, RH similar.
51. Install the 2 rear subframe nuts. Tighten to 150 Nm (111 lb-ft). NOTE: LH shown in illustration, RH similar.
52. Tighten the 2 subframe bracket-to-body bolts to 103 Nm (76 lb-ft). NOTE: LH shown in illustration, RH similar.
53. Install the stabilizer bar links and nuts to the struts. NOTE: LH shown in illustration, RH similar.
54. Install the tie-rod ends and nuts. Tighten to 48 Nm (35 lb-ft). NOTE: LH shown in illustration, RH similar. Install new cotter pins.
55. Install the engine roll restrictor-to-subframe through bolt. Tighten to 90 Nm (66 lb-ft). AWD vehicles
56. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts (3 shown in illustration). Tighten to 70 Nm (52 lb-ft). All vehicles
57. Using new gaskets, install the Y-pipe assembly and the 6 new nuts. Tighten to 40 Nm (30 lb-ft).
58. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
59. Connect the 2 transmission fluid cooler hoses.
60. Connect the power steering cooler tube.
61. 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.
62. If equipped, install the underbody shield and the 6 screws.
63. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
64. Position the LH fender splash shield and install the 4 screws.
65. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 25 Nm (18 lb-ft). NOTE: Align the index marks made during removal.
66. Install the steering joint cover and the 2 nuts.
67. Using a new banjo bolt and 2 new seals, install the PSP tube onto the steering gear. Tighten to 37 Nm (27 lb-ft).
68. Install the PSP tube bracket and bolt. Tighten to 10 Nm (89 lb-in).
69. Connect the PCM connectors and pin-type retainers.
70. Install the engine mount brace and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
71. Install the ground wire and the bolt. Tighten to 10 Nm (89 lb-in).
72. Connect the fuel supply tube to the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-355987) .
73. Attach the power steering reservoir onto the cowl.
74. Connect the hose to the power steering reservoir. Attach the pin-type retainer to the engine mount brace.
75. Install the oil level indicator.
76. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
77. Connect the 2 engine wiring harness electrical connectors.
78. Attach the 2 wiring harness retainers.
79. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 8 Nm (71 lb-in).
80. Install the A/C tube bracket bolt. Tighten to 8 Nm (71 lb-in).
81. Install the 2 A/C tube retaining clamp bolts. Tighten to 10 Nm (89 lb-in).
82. 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).
83. Attach the coolant tube retainer clips to the A/C tube.
84. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
85. Install the ground wire and bolt. Tighten to 12 Nm (106 lb-in).
86. Position the transaxle control cable bracket in place and install the 3 nuts. Tighten to 12 Nm (106 lb-in).
87. Connect the transaxle control cable to the control lever.
88. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
89. Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold.
90. Install the ground wire and the bolt. Tighten to 12 Nm (106 lb-in).
91. Install the 2 battery cables to the positive battery cable and the 2 nuts. Tighten to 9 Nm (80 lb-in).
92. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
93. Connect the 2 engine wiring harness electrical connectors.
94. Install the battery tray. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355968-S25610670162010013000000) .
95. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355993-S28735189342010013000000) .
96. Install the degas bottle. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-355972-S07928583072010013000000) .
97. Install the LH halfshaft and the intermediate shaft. For additional information, refer to «INSTALLATION»(ref-355956-S02551388902010042300000) .
98. Install the accessory drive belt and the power steering belt. For additional information, refer to «INSTALLATION»(ref-355937-S33935887892010013000000) .
99. Fill the engine with clean engine oil. NOTE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
100. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-355972-S37681702192010013000000) .
101. Fill the power steering system. For additional information, refer to «POWER STEERING SYSTEM FILLING»(ref-355933-S06606262842010013000000) .
102. Check the transaxle fluid and add fluid if necessary. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL»(ref-355918-S24459945602010013000000) procedure .
103. Recharge the A/C system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-355932-S05895534102010013000000) .

ITEM SPECIFICATION TABLE

ITEM SPECIFICATION TABLE

ITEM SPECIFICATION TABLE

1. Using the Valve Stem Oil Seal Installer, install a new valve stem seal. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.
2. Using the Valve Spring Compressors, install the valve spring, retainer and key.
3. Install the valve tappets. For additional information, refer to «Removal and Installation»(ref-355916-S42848504822010060800000) .

ITEM SPECIFICATION TABLE

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All vehicles

Scheme 462

Scheme 463

Scheme 464

1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration below in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
2. Install the new M6 bolt. Tighten to 10 Nm (89 lb-in).
3. Install the valve tappets. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation.
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 in illustration below to 10 Nm (89 lb-in). NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
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. Connect the coolant bypass hose to the thermostat housing.
8. 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. NOTE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: The upper and lower O-ring seals are not interchangeable.
9. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
10. Install the RH Camshaft Position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
11. Install the upper intake manifold support bracket and the bolt. Tighten to 10 Nm (89 lb-in). NOTE: Align the bracket with the index mark made during removal.
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). Engines equipped with late build/replacement RH timing chain guides
14. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). Engines equipped with early build RH timing chain guides
15. Install the RH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). All vehicles
16. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
17. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration below: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
18. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
19. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft). All-Wheel Drive (AWD) vehicles
20. Using a new gasket, install the RH catalytic converter and 4 new nuts. NOTE: Do not tighten the 4 catalytic converter nuts at this time.
21. 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 (177 lb-in). Front Wheel Drive (FWD) vehicles
22. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft). All vehicles
23. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
24. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown in illustration ). Tighten to 40 Nm (30 lb-ft).
25. Install the 2 LH catalytic converter bracket bolts. Tighten to 20 Nm (177 lb-in).
26. Connect the LH Catalyst Monitor Sensor (CMS) sensor electrical connector.
27. Connect the CHT sensor electrical connector.
28. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
29. Install the Power Steering Pressure (PSP) tube bracket and bolt. Tighten to 10 Nm (89 lb-in).
30. Connect the RH CMP sensor electrical connector.
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 «Removal and Installation»(ref-355916-S38539097712010060900000) .

ITEM SPECIFICATION TABLE

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.

All vehicles

Scheme 465

Scheme 466

Scheme 467

Scheme 468

1. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in illustration in 5 stages: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 35 Nm (26 lb-ft). Stage 3: Tighten 90 degrees. Stage 4: Tighten 90 degrees. Stage 5: Tighten 90 degrees.
2. Install the new M6 bolt. Tighten to 10 Nm (89 lb-in).
3. Install the valve tappets. NOTE: The valve tappets must be installed in their original positions. NOTE: Coat the valve tappets with clean engine oil prior to installation.
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 in illustration below to 10 Nm (89 lb-in). NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
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. Connect the coolant bypass hose to the thermostat housing.
10. 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. NOTE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: The upper and lower O-ring seals are not interchangeable.
11. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 10 Nm (89 lb-in).
12. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft). All-Wheel Drive (AWD) vehicles
13. Using a new gasket, install the RH catalytic converter and 4 new nuts. NOTE: Do not tighten the 4 catalytic converter nuts at this time.
14. 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 (177 lb-in). Front Wheel Drive (FWD) vehicles
15. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft). All vehicles
16. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
17. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
18. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration below: Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
19. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 10 Nm (89 lb-in).
20. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown in illustration). Tighten to 40 Nm (30 lb-ft).
21. Install the 2 LH catalytic converter bracket bolts. Tighten to 20 Nm (177 lb-in).
22. Install the wiring harness retainer bolt on the rear of the LH cylinder head. Tighten to 10 Nm (89 lb-in).
23. Connect the LH Catalyst Monitor Sensor (CMS) sensor electrical connector.
24. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
25. Connect the LH CMP sensor electrical connector.
26. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
27. Connect the 6 fuel injector electrical connectors (3 shown in illustration).
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 12 Nm (106 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 «Removal and Installation»(ref-355916-S38539097712010060900000) .

ITEM SPECIFICATION TABLE

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles

Scheme 469

Scheme 470

Scheme 471

Scheme 472

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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.
2. Install the oil pan and bolts 10, 11, 13 and 14. Tighten the bolts in the sequence shown in illustration to 3 Nm (27 lb-in). Loosen the bolts 180 degrees. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.
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 in illustration below.
4. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration below, to 3 Nm (27 lb-in).
5. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown in illustration. 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 Alignment Pins.
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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
9. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 3 Nm (27 lb-in). NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
10. Remove the Alignment Pins.
11. Install the engine mount bracket and the 3 bolts. NOTE: Do not tighten the bolt at this time.
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 illustration below 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 (133 lb-in). 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). NOTE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
13. Install the engine mount studs in the following sequence. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material. Clean all the thread sealer from the engine mount studs (old and new studs). Apply new Threadlock and Sealer to the engine mount stud threads. Install the 2 engine mount studs. Tighten to 20 Nm (177 lb-in). NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.
14. Install the engine mount bracket and the 2 bolts. Tighten to 24 Nm (18 lb-ft).
15. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
16. Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the crankshaft pulley. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
17. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 (lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
18. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. NOTE: Spark plug tube seal installation shown in illustration, Variable Camshaft Timing (VCT) solenoid seal installation similar.
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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Early build vehicles
20. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). Late build vehicles
21. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). All vehicles
22. 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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage. Early build vehicles
23. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). Late build vehicles
24. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in). All vehicles
25. Install the wiring harness retaining bracket and the 2 nuts. Tighten to 4 Nm (35 lb-in).
26. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 7 Nm (62 lb-in). NOTE: LH shown in illustration, RH similar.
27. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
28. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 40 Nm (30 lb-ft). Front Wheel Drive (FWD) vehicles
29. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 40 Nm (30 lb-ft). All vehicles
30. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown in illustration). Tighten to 40 Nm (30 lb-ft).
31. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 11 Nm (97 lb-in).
32. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
33. Install the Power Steering Pressure (PSP) hose bracket and nut. Tighten to 9 Nm (80 lb-in).
34. Attach the PSP hose retainer to the engine lifting eye.
35. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
36. Connect the LH camshaft VCT solenoid electrical connector.
37. Connect the 3 LH coil-on-plug electrical connectors.
38. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.
39. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
40. Connect the 3 RH coil-on-plug electrical connectors.
41. Connect the RH VCT solenoid electrical connector. FWD vehicles
42. Connect the RH CMS electrical connector. All vehicles
43. Connect the PSP switch electrical connector.
44. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
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 (TB) electrical connector.
48. Connect the PCV hose to the PCV valve.
49. 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.
50. If equipped, connect the block heater electrical connector and install the heat shield.
51. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
52. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
53. Install the crankshaft sensor ring.
54. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).
55. Install the engine in the vehicle. For additional information, refer to «ENGINE»(ref-355916-S17586466302010013000000) .

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.

Scheme 473

1. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
2. Install the oil pan. For additional information, refer to «Removal and Installation»(ref-355916-S06514381152010060800000) .

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.

Scheme 474

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). NOTE: Install a new oil pump screen and pickup tube O-ring seal prior to installing the oil pump.
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 lockpin.
8. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
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 in illustration below to 10 Nm (89 lb-in). NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
12. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown in illustration below to 10 Nm (89 lb-in). NOTE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
13. Install the engine front cover. For additional information, refer to «Removal and Installation»(ref-355916-S07935742642010060800000) .

ITEM SPECIFICATION TABLE

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.

Scheme 475

Scheme 476

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. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage. NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.
2. Install the rear seal retainer and the 8 bolts in the sequence shown in illustration below. Tighten in the sequence shown in illustration below 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. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
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 «Removal and Installation»(ref-355916-S06514381152010060800000) .
9. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.