Section 421 (Engine - 3.0L): Assembly: Engine: Material

1. Install the components in the order indicated in the following illustration and table. See Fig 1.
   Fig 1: Removing LH Cylinder Head

   Courtesy of FORD MOTOR CO.
2. Install the components in the order indicated in the following illustration and table. See Fig 2.
   Fig 2: Removing Timing Chain Crankshaft Sprocket

   Courtesy of FORD MOTOR CO.
3. Install the components in the order indicated in the following illustration and table. See Fig 3.
   Fig 3: Removing LH Timing Chain

   Courtesy of FORD MOTOR CO.
4. Install the components in the order indicated in the following illustration and table. See Fig 4.
   Fig 4: Removing VCT Solenoid Housing Assembly

   Courtesy of FORD MOTOR CO.
5. Install the components in the order indicated in the following illustration and table. See Fig 5.
   Fig 5: Removing RH Timing Chain

   Courtesy of FORD MOTOR CO.
6. Install the components in the order indicated in the following illustration and table. See Fig 6.
   Fig 6: Removing Engine Front Cover Gaskets

   Courtesy of FORD MOTOR CO.
7. Install the components in the order indicated in the following illustration and table. See Fig 7.
   Fig 7: Removing Oil Pan

   Courtesy of FORD MOTOR CO.
8. Install the components in the order indicated in the following illustration and table. See Fig 8.
   Fig 8: Removing RH Valve Cover

   Courtesy of FORD MOTOR CO.
9. Install the components in the order indicated in the following illustration and table. See Fig 9.
   Fig 9: Removing LH Valve Cover

   Courtesy of FORD MOTOR CO.
10. Install the components in the order indicated in the following illustration and table. See Fig 10.
    Fig 10: Removing Lower Intake Manifold Gaskets

    Courtesy of FORD MOTOR CO.
11. Install the components in the order indicated in the following illustration and table. See Fig 11.
    Fig 11: Removing RH Exhaust Manifold

    Courtesy of FORD MOTOR CO.
12. Install the components in the order indicated in the following illustration and table. See Fig 12.
    Fig 12: Identifying Oil Filter Adapter

    Courtesy of FORD MOTOR CO.
13. Install the components in the order indicated in the following illustration and table. See Fig 13.
    Fig 13: Identifying A/C Compressor

    Courtesy of FORD MOTOR CO.
14. Install the components in the order indicated in the following illustration and table. See Fig 14.
    Fig 14: Removing LH Exhaust Manifold

    Courtesy of FORD MOTOR CO.
15. Install the components in the order indicated in the following illustration and table. See Fig 15.
    Fig 15: Identifying Ignition Coil

    Courtesy of FORD MOTOR CO.
16. Install the components in the order indicated in the following illustration and table. See Fig 16.
    Fig 16: Removing Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
17. Install the components in the order indicated in the following illustration and table. See Fig 17.
    Fig 17: Removing Engine Wire Harness

    Courtesy of FORD MOTOR CO.
18. Install the components in the order indicated in the following illustration and table. See Fig 18.
    Fig 18: Removing Fuel Vapor Hose

    Courtesy of FORD MOTOR CO.
19. Install the components in the order indicated in the following illustration and table. See Fig 19.
    Fig 19: Removing Coolant Pump

    Courtesy of FORD MOTOR CO.
20. Install the components in the order indicated in the following illustration and table. See Fig 20.
    Fig 20: Removing EGR System Module

    Courtesy of FORD MOTOR CO.
21. Install the components in the order indicated in the following illustration and table. See Fig 21.
    Fig 21: Removing Flexplate

    Courtesy of FORD MOTOR CO.

Item 1: Engine Assembly Note 

1. Rotate the crankshaft to position the keyway at the nine o'clock position.
   Fig 22: Rotating Crankshaft Keyway To 9 O'Clock Position

   Courtesy of FORD MOTOR CO.
2. Position the oil pump and install the bolts.
   Fig 23: Installing Oil Pump

   Courtesy of FORD MOTOR CO.
3. Position the oil pan baffle and install the nuts. Tighten in two stages:
   • Stage 1: Tighten to 5 N.m (44 lb-in).
   • Stage 2: Tighten an additional 45 degrees.
   Fig 24: Installing Oil Pan Baffle

   Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil before installing.
Fig 25: Installing Oil Pump Screen Cover
Courtesy of FORD MOTOR CO.
4. Position the oil pump screen cover and tube and install the bolts.
   • Use a new O-ring seal, if necessary.
5. Position the top-mounted knock sensor (KS) and install the bolt.
   Fig 26: Installing Top-Mounted Knock Sensor

   Courtesy of FORD MOTOR CO.
6. Using a new O-ring seal, position the coolant inlet tube and install the bolts.
   Fig 27: Installing O-Ring Seal

   Courtesy of FORD MOTOR CO.

Items 2-7: LH and RH Cylinder Head, Gaskets and Bolts Assembly Note 

CAUTION: The cylinder head gasket surfaces are ground to a precision finish. Do not rest cylinder heads on gasket surfaces. Do not use any abrasive materials during cleaning of the surfaces. Hairline scratches, small burrs, or dirt can provide a leak path for a cylinder head gasket to leak. If gasket material remains on the sealing surface, use only a plastic-tipped scraper to remove the material. Do not attempt to reuse the head gaskets.
CAUTION: Cylinder head bolts are torque-to-yield and cannot be reused.
NOTE: The LH and RH cylinder head gaskets are not interchangeable.
Fig 28: Installing Cylinder Head
Courtesy of FORD MOTOR CO.
1. Using a new cylinder head gasket, position the cylinder head, and install new bolts.
   • Tighten the bolts in six stages:
     • Stage 1: Tighten to 30 N.m (22 lb-ft).
     • Stage 2: Tighten an additional 90 degrees.
     • Stage 3: Back out a minimum of one full turn (360 degrees).
     • Stage 4: Tighten to 30 N.m (22 lb-ft).
     • Stage 5: Tighten an additional 90 degrees.
     • Stage 6: Tighten an additional 90 degrees.
NOTE: LH is shown; RH is similar.
Fig 29: Installing LH And RH Spark Plugs
Courtesy of FORD MOTOR CO.
2. Install the LH and RH spark plugs.
NOTE: Be sure camshaft bearing caps are installed in their original positions.
Fig 30: Installing Camshafts Into Cylinder Head
Courtesy of FORD MOTOR CO.
3. Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head.
CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
Fig 31: Installing Camshaft Bearing Caps
Courtesy of FORD MOTOR CO.
4. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil, install the bearing caps, and loosely install the bolts.
5. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil, install the caps, and loosely install the bolts.
   Fig 32: Installing Camshaft Bearing Thrust Caps

   Courtesy of FORD MOTOR CO.
6. Tighten the bolts in the sequence shown. See Fig 33.
   Fig 33: Tightening Bolts Sequence

   Courtesy of FORD MOTOR CO.
NOTE: If new camshafts were installed, refer to VALVE CLEARANCE ADJUSTMENT  in this section.
7. Lubricate the tappet shims and camshaft lobes with clean engine oil.
8. Rotate the camshafts to make sure they are not binding. If binding occurs, check to make sure that all bearing caps are in their original positions. Loosen all bearing cap bolts in reverse order and retighten.
NOTE: Lubricate the O-ring seal with clean engine coolant.
9. Install the coolant outlet pipe, a new O-ring seal and the 2 bolts.
   • Tighten to 25 N.m (18 lb-ft).
Fig 34: Installing O-Ring Seal
Courtesy of FORD MOTOR CO.

Items 8-19: Variable Camshaft Timing (VCT) Actuators, Exhaust Camshaft Sprockets, Bolts, Washers and Crankshaft Sprockets Assembly Note 

1. With the two keyways facing forward, install the crankshaft sprockets.
   Fig 35: Installing Crankshaft Sprockets

   Courtesy of FORD MOTOR CO.
2. Install the LH exhaust camshaft sprocket and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages.
   • Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 N.m (15 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
   Fig 36: Installing LH Exhaust Camshaft Sprocket

   Courtesy of FORD MOTOR CO.
3. Install the LH variable camshaft timing (VCT) actuator and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages.
   • Stage 1: Tighten the VCT actuator bolt to 20 N.m (15 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
   Fig 37: Installing LH Variable Camshaft Timing

   Courtesy of FORD MOTOR CO.
4. Install the RH exhaust camshaft sprocket and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages.
   • Stage 1: Tighten the exhaust camshaft sprocket bolt to 20 N.m (15 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
   Fig 38: Installing RH Exhaust Camshaft Sprocket

   Courtesy of FORD MOTOR CO.
5. Install the RH variable camshaft timing (VCT) actuator and a new bolt hand tight. Using a wrench on the flats of the camshaft, hold the camshaft in position and tighten the bolt in two stages.
   • Stage 1: Tighten the VCT actuator bolt to 20 N.m (15 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
   Fig 39: Installing RH Variable Camshaft Timing

   Courtesy of FORD MOTOR CO.

Items 20-33: Timing Drive Components Assembly Note 

1. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
   1. Mark any link to use as the exhaust camshaft timing mark.
   2. Starting with the exhaust camshaft timing mark, count 16 links and mark the link as the intake camshaft sprocket timing mark.
   3. Starting with the intake camshaft timing mark, count 25 links and mark the link as the crankshaft sprocket timing mark.
   Fig 40: Aligning Crankshaft Sprocket Timing Mark

   Courtesy of FORD MOTOR CO.
2. Verify that the crankshaft keyway is in the eleven o'clock position.
   Fig 41: Rotating Crankshaft Keyway To 11 O'Clock Position

   Courtesy of FORD MOTOR CO.
CAUTION: The crankshaft keyway must remain in the eleven o'clock position until the cams are located in the neutral position, or damage to the valves can occur.
Fig 42: Rotating LH And RH Intake And Exhaust Camshafts
Courtesy of FORD MOTOR CO.
3. Rotate the LH and RH intake and exhaust camshafts to locate them in their neutral positions.
NOTE: Gold-colored bolt (No. 2 location) must be installed in its original location.
Fig 43: Installing LH VCT Solenoid Housing Assembly
Courtesy of FORD MOTOR CO.
4. Install the LH VCT solenoid housing assembly and hand-tighten the bolts.
   • Tighten in the sequence shown to 25 N.m (18 lb-ft).
5. Install the LH timing chain, aligning the copper (or marked) link with the marks on the camshaft and crankshaft sprockets.
   Fig 44: Installing Camshaft And Crankshaft Sprockets

   Courtesy of FORD MOTOR CO.
6. Install the LH timing chain tensioner arm.
   Fig 45: Installing LH Timing Chain Tensioner Arm

   Courtesy of FORD MOTOR CO.
NOTE: Be sure to position the tensioner so that the tensioner piston is fully engaged in the tensioner arm.
Fig 46: Installing LH Timing Chain Tensioner And Bolts
Courtesy of FORD MOTOR CO.
7. Install the LH timing chain tensioner and bolts.
8. Remove the wire or paper clip from the tensioner.
   Fig 47: Removing Paper Clip From Tensioner

   Courtesy of FORD MOTOR CO.
9. Rotate the crankshaft clockwise and position the keyway at the three o'clock position for RH timing chain installation.
   Fig 48: Rotating Crankshaft Keyway To 3 O'Clock Position

   Courtesy of FORD MOTOR CO.
10. Verify that the copper (or marked) links on the LH timing chain are in alignment with the timing index marks on the camshaft and crankshaft sprockets.
    Fig 49: Aligning Camshaft And Crankshaft Sprockets

    Courtesy of FORD MOTOR CO.
11. Install the RH VCT solenoid housing assembly and hand-tighten the bolts.
    • Tighten in the sequence shown to 25 N.m (18 lb-ft).
    Fig 50: Installing RH VCT Solenoid Housing Assembly

    Courtesy of FORD MOTOR CO.
12. Install the RH timing chain, aligning the copper (or marked) links with the marks on the camshaft and crankshaft sprockets.
    Fig 51: Installing RH Timing Chain

    Courtesy of FORD MOTOR CO.
13. Install the RH timing chain tensioner arm.
    Fig 52: Installing RH Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
14. Install the RH timing chain tensioner and bolts.
    Fig 53: Installing RH Timing Chain Tensioner And Bolts

    Courtesy of FORD MOTOR CO.
15. Remove the wire or paper clip from the RH timing chain tensioner.
    Fig 54: Removing RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
16. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the 11 o'clock position.
    Fig 55: Rotating Crankshaft Keyway To 11 O'Clock Position

    Courtesy of FORD MOTOR CO.
CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.
Fig 56: Aligning Crankshaft Timing Marks
Courtesy of FORD MOTOR CO.
17. Verify that the timing component alignment is correct.
    1. There should be LH chain links between the exhaust and intake camshaft timing marks.
    2. There should be 23 chain links between the camshaft and crankshaft timing marks.
    3. There should be 28 chain links between the camshaft and crankshaft timing marks.
18. Remove the crankshaft damper bolt and washer.
    Fig 57: Removing Crankshaft Damper Bolt And Washer

    Courtesy of FORD MOTOR CO.
CAUTION: This pulse wheel is used with several different engines. Install the pulse wheel with the keyway in the slot stamped "20-25-30 DAMB 30 RFF" only. This slot is also marked with an orange paint mark and aligns with the missing tooth in the trigger wheel.
Fig 58: Installing Ignition Pulse Wheel
Courtesy of FORD MOTOR CO.
19. Install the ignition pulse wheel using the orange marked keyway slot and the teeth facing forward.

Items 20 and 27: VCT System Oil Filters Assembly Note 

NOTE: LH is shown, RH is similar.
Fig 59: Removing Variable Camshaft Timing
Courtesy of FORD MOTOR CO.
1. Remove the bolt and the variable camshaft timing (VCT) solenoid.
2. Remove the VCT system filter cap and replace the VCT system filter.
   Fig 60: Removing VCT System Filter Cap

   Courtesy of FORD MOTOR CO.
3. Repeat the previous steps for the RH VCT system filter.

Items 34 and 35: Engine Front Cover and Front Cover Gaskets Assembly Note 

1. Clean the engine front cover to cylinder block and cylinder head sealing surfaces, using a clean shop towel and metal surface cleaner to remove all residue.
   Fig 61: Cleaning Engine Front Cover To Cylinder Block And Cylinder Head Sealing Surfaces

   Courtesy of FORD MOTOR CO.
2. Install new front cover seals into the front cover.
NOTE: Install the engine front cover and bolts no more than four minutes after applying sealer.
Fig 62: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.
3. Apply a 6 mm (0.24 in) diameter dot of silicone gasket and sealant to the areas shown.
NOTE: Fastener No. 14 is a stud bolt.
Fig 63: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.
4. Install the engine front cover and the bolts.
   • Tighten the bolts in the sequence shown.

Items 36-39: Oil Pan Gasket, Oil Pan, Oil Pan Stud and Bolts Assembly Note 

1. Rotate the engine upside down on the engine stand.
2. Clean the oil pan-to-cylinder block sealing surfaces on the oil pan and cylinder block with a clean shop towel and metal surface cleaner to remove all residue.
NOTE: Install the oil pan and bolts no more than four minutes after applying sealer.
Fig 64: Installing Oil Pan
Courtesy of FORD MOTOR CO.
3. Apply a 10 mm (0.4 in) dot of silicone gasket and sealant onto the top of the new oil pan gasket at the two locations shown.
NOTE: The oil pan rear face must be installed flush to the cylinder block rear face to within +/- 0.10 mm (0.0039 in). Failure to maintain this specification will require the oil pan to be removed and installed again.
Fig 65: Installing Oil Pan With Rear Face Of Cylinder Block
Courtesy of FORD MOTOR CO.
4. Install the oil pan.
   • Using a straightedge, align the rear face of the oil pan with the rear face of the cylinder block.
5. Tighten the oil pan bolts in the sequence shown. See Fig 66.
   Fig 66: Tightening Oil Pan Sequence

   Courtesy of FORD MOTOR CO.

Items 40 and 41: RH Valve Cover and Gaskets Assembly Note 

1. Install a new gasket in the RH valve cover.
NOTE: Install the valve cover and bolts no more than four minutes after applying the sealer.
Fig 67: Installing Valve Cover
Courtesy of FORD MOTOR CO.
2. Apply an 8 mm (0.32 in) bead of silicone gasket and sealant to the cylinder half round surface and to the front cover gasket intersection places.
3. Position the RH valve cover and install the bolts in the sequence shown.
   Fig 68: Installing RH Valve Cover

   Courtesy of FORD MOTOR CO.

Items 44 and 45: LH Valve Cover and Gaskets Assembly Note 

1. Install a new gasket in the LH valve cover.
NOTE: Install the valve cover and bolts no more than four minutes after installing the sealer.
Fig 69: Applying Silicone Gasket And Sealer
Courtesy of FORD MOTOR CO.
2. Apply an 8 mm (0.32 in) bead of silicone gasket and sealer to the cylinder half round surface and to the front cover gasket intersection places.
3. Position the LH valve cover and install the bolts in the sequence shown. See Fig 70.
   Fig 70: Installing LH Valve Cover

   Courtesy of FORD MOTOR CO.

Items 47-49: Lower Intake Manifold Assembly, Gaskets and Bolts Assembly Note 

1. Inspect the lower intake manifold gaskets. Install new gaskets if necessary.
   Fig 71: Installing Lower Intake Manifold Gaskets

   Courtesy of FORD MOTOR CO.
2. Position the lower intake manifold assembly and install the bolts in the sequence shown.
   Fig 72: Installing Lower Intake Manifold Assembly

   Courtesy of FORD MOTOR CO.

Items 57 and 58: RH Exhaust Manifold and Nuts Assembly Note 

1. Position the RH engine mount bracket and install the bolts.
   Fig 73: Installing RH Engine Mount Bracket

   Courtesy of FORD MOTOR CO.
2. Using a new gasket, position the RH exhaust manifold and install the nuts.
   Fig 74: Installing RH Exhaust Manifold And Install Nuts

   Courtesy of FORD MOTOR CO.

Items 68: Oil Filter Assembly Note 

1. Using an oil filter strap wrench, install the oil filter until the seal makes contact. Tighten an additional 270 degrees.

Item 77: Crankshaft Front Oil Seal Assembly Note 

1. Using the special tool, install the crankshaft front oil seal.
   Fig 75: Installing Crankshaft Front Oil Seal

   Courtesy of FORD MOTOR CO.

Items 78-80: Crankshaft Pulley, Bolt, and Washer Assembly Note 

NOTE: Install the crankshaft damper no more than four minutes after applying the sealer.
Fig 76: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
1. Apply a dot of silicone gasket and sealant to the crankshaft damper keyway slot.
2. Using the special tool, install the crankshaft damper.
   Fig 77: Installing Crankshaft Damper

   Courtesy of FORD MOTOR CO.
3. Using the special tool, install the washer and a new bolt. See Fig 78.

   Tighten the bolt in four stages:

   • Stage 1: Tighten to 120 N.m (89 lb-ft).
   • Stage 2: Back out a minimum of one full turn (360 degrees).
   • Stage 3: Tighten to 50 N.m (37 lb-ft).
   • Stage 4: Tighten an additional 90 degrees.
   Fig 78: Tightening Crankshaft Damper Bolt

   Courtesy of FORD MOTOR CO.

Items 81 and 82: LH Exhaust Manifold and Nuts Assembly Note 

1. Position the LH engine mount bracket and install the bolts.
   Fig 79: Installing LH Engine Mount Bracket

   Courtesy of FORD MOTOR CO.
2. Using a new gasket, position the LH exhaust manifold and install the nuts.
   Fig 80: Installing LH Exhaust Manifold

   Courtesy of FORD MOTOR CO.

Items 92-99: Upper Intake Manifold, Gaskets and Bolts, and Fuel Regulator Shield and Bolts Assembly Note 

1. Position the upper intake manifold and gaskets. Install the bolts finger tight.
   Fig 81: Installing Upper Intake Manifold And Gaskets

   Courtesy of FORD MOTOR CO.
2. Position the fuel pressure sensor shield and install the bolts finger tight.
3. Tighten the upper intake bolts in the sequence shown.
   Fig 82: Installing Fuel Pressure Sensor Shield

   Courtesy of FORD MOTOR CO.

Item 104: Engine Wiring Harness Assembly Note 

1. Position the ground strap and install the nut.
   Fig 83: Installing Ground Strap

   Courtesy of FORD MOTOR CO.
2. Install the bracket and the nut.
   Fig 84: Installing Bracket

   Courtesy of FORD MOTOR CO.
3. Position the wiring harness and install the four nuts.
   Fig 85: Installing Wiring Harness

   Courtesy of FORD MOTOR CO.
4. Position the two radio ignition interference capacitors and install the bolts.
   Fig 86: Positioning Radio Ignition Interference Capacitor

   Courtesy of FORD MOTOR CO.
5. Attach the wiring harness retainer.
   Fig 87: Attaching Wiring Harness Retainer

   Courtesy of FORD MOTOR CO.
6. Clip the two wiring harness retainers into the brackets and connect the generator electrical connector.
   Fig 88: Connecting Generator Electrical Connector

   Courtesy of FORD MOTOR CO.
7. Position the wiring harness and install the nut.
   Fig 89: Positioning Wiring Harness

   Courtesy of FORD MOTOR CO.
8. Attach the three wiring harness retainers.
   Fig 90: Attaching Wiring Harness Retainers

   Courtesy of FORD MOTOR CO.
9. Attach the three wiring harness retainers.
   Fig 91: Attaching Wiring Harness Retainers

   Courtesy of FORD MOTOR CO.
10. Connect the A/C electrical connector.
    Fig 92: Connecting A/C Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Connect the oil pressure switch electrical connector.
    Fig 93: Connecting Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
NOTE: LH is shown, RH is similar.
Fig 94: Connecting Camshaft Position (CMP) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
12. Connect the two camshaft position (CMP) sensor electrical connectors.
13. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 95: Connecting Camshaft Position (CKP) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
14. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 96: Connecting Camshaft Position (CHP) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
15. Connect the fuel injector wiring harness connector.
    Fig 97: Connecting Fuel Injector Wiring Harness Connector

    Courtesy of FORD MOTOR CO.
16. Connect the intake manifold tuning valve electrical connectors.
    Fig 98: Connecting Intake Manifold Tuning Valve Electrical Connectors

    Courtesy of FORD MOTOR CO.
17. Connect the throttle body electrical connectors.
    Fig 99: Connecting Throttle Body Electrical Connectors

    Courtesy of FORD MOTOR CO.

Item 106: Emissions Vacuum Hose Assembly Note 

1. Connect the fuel pressure sensor jumper to the main vacuum harness.
   Fig 100: Connecting Fuel Pressure Sensor Jumper

   Courtesy of FORD MOTOR CO.
2. Connect the positive crankcase ventilation (PCV) tube at the rear of the upper intake manifold.

Item 119: EGR System Module Gasket Assembly Note 

1. Install a new EGR system module gasket with the side with the raised circle facing the intake manifold.
   Fig 101: Installing EGR System Module Gasket Assembly

   Courtesy of FORD MOTOR CO.

Item 125: Crankshaft Rear Oil Seal Assembly Note 

1. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with clean engine oil.
2. Using the special tools, install the crankshaft rear oil seal.
   Fig 102: Installing Crankshaft Rear Oil Seal

   Courtesy of FORD MOTOR CO.

Items 126-128: Flexplate Bolts, Flexplate, and Spacer Plate Assembly Note 

1. Install the special tool onto the engine as shown.
   Fig 103: Installing Special Tool Onto Engine (1 Of 2)

   Courtesy of FORD MOTOR CO.
2. Install the special tool onto the engine as shown.
   Fig 104: Installing Special Tool Onto Engine (2 Of 2)

   Courtesy of FORD MOTOR CO.
3. Using the special tool and an engine crane, transfer the engine from the stand to the floor or a bench.
4. Install the spacer plate assembly.
   Fig 105: Installing Spacer Plate Assembly

   Courtesy of FORD MOTOR CO.
5. Attach both the wiring harness retainers, one on each side of the engine.
   Fig 106: Connecting Wiring Harness Retainers

   Courtesy of FORD MOTOR CO.
6. Install the flywheel and the bolts.
   Fig 107: Installing Flywheel

   Courtesy of FORD MOTOR CO.