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Engine (Except Block)

Special Tools

Illustration Tool Name Tool Number
GF0000536
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0008917
 Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
GF0008919
 Timing Peg, Crankshaft 303-507
GF0008918
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
GF0008916
 Adapter for 205-126 (205-072-02)
GF0008927
 Installer, Front Oil Seal 303-096 (T74P-6150-A)
GF0008974
 Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)
GF0009070
 Aligner, Clutch Disc 308-006 (T71P-7137-H)
Material

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
Motorcraft Metal Surface Cleaner
ZC-21		 WSE-M5B392-A
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Silicone Gasket Remover
ZC-30		 -
Motorcraft Metal Surface Prep ZC-31
 		 -
Silicone Brake Caliper Grease and Dielectric Compound
XG-3-A		 ESE-M1C171-A
Motorcraft Premium Engine Coolant with Bittering Agent (US); Motorcraft Premium Quality Antifreeze/Coolant (Canada)
VC-5 (US); CXC-10 (Canada); or equivalent (green color)		 ESE-M97B44-A
High Temperature 4x4 Front Axle and Wheel Bearing Grease
E8TZ-19590-A		 ESA-M1C198-A
Fig 1: Exploded View Of Lower Engine Block (View 1)
GF0028853Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6010 Cylinder block
2 6K318 Crankshaft rear oil seal and retainer
3 6477 Flywheel
4 6675 Oil pan
5 6622 Oil pump screen and pickup tube
6 8575 Thermostat assembly
7 6A785 Crankcase vent oil separator
8 6884 Oil filter adapter
9 6A636 Oil filter adapter gasket
Fig 2: Identifying Lower Engine Block Components (View 2)
G06262224
ITEM DESCRIPTION

Item Part Number Description
1 6161 Piston oil control spacer (4 required)
2 6150 Piston compression upper ring (4 required)
3 6152 Piston compression lower ring (4 required)
4 6159 Piston oil control upper segment ring (4 required)
5 6159 Piston oil control lower segment ring (4 required)
6 6140 Piston pin retainer (8 required)
7 6135 Piston pin (4 required)
8 6200 Connecting rod (4 required)
9 6211 Connecting rod upper bearing (4 required)
10 6110 Piston (4 required)
11 6211 Connecting rod lower bearing (4 required)
12 6210 Connecting rod cap (4 required)
13 6010 Cylinder block
14 6333 Cylinder block crankshaft main bearing (5 required)
15 6303 Crankshaft
16 6333 Crankshaft main bearing beam bearing (5 required)
17 6F098 Main bearing beam
18 6K360 Balance shaft assembly
Fig 3: Exploded View Of Front Engine Block
GF0028854Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6B209 Accessory drive belt tensioner
2 10300 Generator
3 8501 Coolant pump and pulley
4 6C315 Crankshaft position (CKP) sensor
5 6A340 Crankshaft pulley bolt
6 6316 Crankshaft pulley
7 6C348 Idler pulley
8 6C348 Idler pulley (without A/C only)
9 6700 Crankshaft front seal
10 6019 Engine front cover
11 6K254 Timing chain tensioner
12 6K255 Timing chain tensioner arm
13 6268 Timing chain
14 6K297 Timing chain guide
15 6C271 Oil pump chain tensioner
16 6M256 Oil pump chain guide (early build)
17 6A895 Oil pump chain
18 6652 Oil pump drive gear
19 6378 Diamond washer
20 6306 Crankshaft sprocket
21 6378 Diamond washer
22 6600 Oil pump
23 6010 Cylinder block
Fig 4: Exploded View Of Cylinder Head
GF0028855Courtesy of FORD MOTOR CO.
Item Part Number Description
1 12A366 Coil-on-plug assembly (4 required)
2 6766 Oil filler cap
3 12K073 Camshaft position (CMP) sensor
4 6M293 Valve cover
5 6M293 Valve cover gasket
6 6M280 Variable camshaft timing (VCT) solenoid
7 6A284 Camshaft bearing caps (9 required)
8 6A258 Camshaft bearing cap
9 6A272 Camshaft (exhaust)
10 6A271 Camshaft (intake)
11 6C251 Camshaft sprocket
12 6C525 VCT actuator
13 6500 Valve tappet (16 required)
14 6518 Valve collet (16 required)
15 6514 Valve spring retainer (16 required)
16 6513 Valve spring (16 required)
17 6A517 Valve stem seal (16 required)
18 6G004 Cylinder head temperature (CHT) sensor
19 12405 Spark plug (4 required)
20 6065 Cylinder head bolt (10 required)
21 6049 Cylinder head
22 6505 Exhaust valve (8 required)
23 6507 Intake valve (8 required)
24 6051 Head gasket
25 6010 Cylinder block
26 9448 Catalytic converter gasket (with secondary air injection)
27 5E211 Catalytic converter (with secondary air injection)
28 - Heat shield (with secondary air injection)
29 9448 Catalytic converter gasket (without secondary air injection)
30 5E211 Catalytic converter (without secondary air injection)
31 - Heat shield (without secondary air injection)
Fig 5: Exploded View Of Intake Manifold
GF0028856Courtesy of FORD MOTOR CO.
Item Part Number Description
1 8K556 Coolant outlet
2 9D475 Exhaust gas recirculation (EGR) valve
3 9F991 Throttle body
4 6051 Cylinder head gasket
5 6010 Cylinder block
6 12A699 Knock sensor (KS)
7 9424 Intake manifold
8 9439 Intake manifold gasket
9 8A582 Coolant hose
10 6049 Cylinder head
11 9F593 Fuel injector (4 required)
12 9H487 Fuel rail
13 - Fuel rail insulator
CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
CAUTION: 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 are equipped with an oil pump drive chain guide. Late build engines do not have an oil pump drive chain guide. Also, late build engines use an updated design for the oil pump drive chain and tensioner. Therefore, the oil pump drive components are not interchangeable between early build and late build engines.

All vehicles 

  1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.
    NOTE: The front bulkhead does not have an oil squirter.

    Install the 4 oil squirters.

    • Tighten to 4 Nm (35 lb-in).
    Fig 6: Locating Oil Squirters
    G06262228
  2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
    Fig 7: Identifying Measuring Directions Of Crankshaft Main Bearing Journal Diameter
    G06262229
  3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    Fig 8: Locating Main Bearing Beam
    G06262230
  4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
    Fig 9: Identifying Main Bearing Beam Bolts Tightening Sequence
    G06262231
  5. Measure each crankshaft block main bearing bore diameter.
    • Remove the bolts and the main bearing beam.
    • Discard the main bearing beam bolts.
    Fig 10: Identifying Crankshaft Block Main Bearing Bore Diameter
    G06262232
  6. Using the chart, select the crankshaft main bearings.
    Fig 11: Crankshaft Main Bearings Chart
    G06262233
  7. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Using the original connecting rod cap bolts, install the connecting caps and bolts.

    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
    • Remove the bolts and the connecting rod cap.
    • Discard the connecting rod cap bolts.
    Fig 12: Identifying Connecting Rod Large End Bore Measuring Directions
    G06262234
  9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
    Fig 13: Identifying Measuring Directions Of Crankshaft Connecting Rod Bearing Journal Diameters
    G06262235
  10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    Fig 14: Connecting Rod Bearings Chart
    G06262236
  11. 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.
    NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
    NOTE: The center bulkhead is the thrust bearing.

    Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.

    Fig 15: Locating Upper Crankshaft Main Bearings
    G06262237
  12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

    Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.

    Fig 16: Locating Crankshaft Main Bearings
    G06262238
  13. Lubricate journals on the crankshaft with clean engine oil.
  14. Position the crankshaft in the cylinder block.
    Fig 17: Locating Crankshaft
    G06262239
  15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
    Fig 18: Locating Main Bearing Beam Side Fit Surfaces
    G06262240
  16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    Fig 19: Locating Main Bearing Beam
    G06262241
  17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
    NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

    Install and tighten the 10 new main bearing beam bolts.

    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
    Fig 20: Identifying Main Bearing Beam Bolts Tightening Sequence
    G06262242
  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 with Holding Fixture.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
    Fig 21: Measuring Crankshaft End Play
    G06262243
  19. 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: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
    NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

    Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.

    • When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
    • The position of the upper and lower compression ring gaps are not controlled for installation.
    Fig 22: Identifying Piston Ring Compressor And Connecting Rod Installer
    G06262244
  20. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
    NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

    Install the connecting rod caps and the new bolts.

    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 23: Locating Connecting Rod Cap Bolts
    G06262245
  21. Install the Crankshaft TDC  Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg. The engine is now at Top Dead Center (TDC).
    Fig 24: Installing Crankshaft TDC Timing Peg
    G06262246
  22. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
    NOTE: The original adjustment shims must be installed in their original position.
    NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.

    Install the adjustment shims in their original position on the seat faces of the balancer unit.

  23. With the balancer unit shaft marks in the TDC  position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
    Fig 25: Locating Balancer Unit And Shafts Reference Mark
    G06262247
  24. Install the balancer unit bolts.
    • Tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten to 25 Nm (18 lb-ft).
    • Stage 2: Tighten to 50 Nm (37 lb-ft).
    Fig 26: Identifying Balancer Unit Bolts Tightening Sequence
    G06262248
  25. Remove the Crankshaft TDC  Timing Peg.
    Fig 27: Installing Crankshaft TDC Timing Peg
    G06262249
  26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
  27. Install the Crankshaft TDC  Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg.
    • Remove the Crankshaft TDC  Timing Peg.
    Fig 28: Installing Crankshaft TDC Timing Peg
    G06262250
  28. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown.

    Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.

    • Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
    • Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
    • If the backlash exceeds the specified range, carry out the balance shaft backlash procedure. For additional information, refer to the Balance Shaft Backlash  procedure in this section.
    Fig 29: Measuring Gear Backlash
    G06262251
    29. WARNING: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  29. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
  30. Remove the engine plug bolt.
    31. Fig 30: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
  31. Install the special tool.
    32. Fig 31: Identifying Special Tool (303-507)
    GF0028857Courtesy of FORD MOTOR CO.
    NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
  32. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    33. Fig 32: Identifying Oil Pump Bolts Tightening Sequence
    GF0008969Courtesy of FORD MOTOR CO.
  33. Install a new gasket, oil pump pickup tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    34. Fig 33: Locating Oil Pump Pickup Tube Bolts
    GF0024195Courtesy of FORD MOTOR CO.
  34. Using the special tool, install the crankshaft rear main oil seal.
    35. Fig 34: Positioning Crankshaft Rear Oil Seal Using Special Tool (303-328)
    GF0008975Courtesy of FORD MOTOR CO.
  35. Tighten the 6 crankshaft rear main oil seal bolts in the sequence shown.
    • To install, tighten to 10 Nm (89 lb-in).
    36. Fig 35: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
    GF0008976Courtesy of FORD MOTOR CO.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.
  36. Clean and inspect all mating surfaces.
    37. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  37. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
    • Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
    38. Fig 36: Identifying Rear Oil Pan Bolts
    G03897723Courtesy of FORD MOTOR CO.
  38. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
    39. Fig 37: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block Using Suitable Straightedge
    GF0024104Courtesy of FORD MOTOR CO.
  39. Install the remaining oil pan bolts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
    40. Fig 38: Identifying Tightening Sequence Of Oil Pan Bolts
    G03897725Courtesy of FORD MOTOR CO.
  40. Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    41. Fig 39: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    CAUTION: Observe all warnings and 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.
  41. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. 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.
    4. Apply metal surface prep, following package directions, to remove any 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.
  42. Apply silicone gasket and sealant to the locations shown.
    43. Fig 40: Identifying Silicone Gasket And Sealant Location
    G03897827Courtesy of FORD MOTOR CO.
  43. Install a new head gasket.
    44. Fig 41: Identifying Head Gasket
    GF0024202Courtesy of FORD MOTOR CO.
    NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    NOTE: Lubricate the bolts with clean engine oil prior to installation.
  44. Install 10 new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
    • Stage 1: Tighten to 7 Nm (62 lb-in).
    • Stage 2: Tighten to 15 Nm (11 lb-ft).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
    45. Fig 42: Identifying Tightening Sequence Of Cylinder Head Bolts
    GF0008958Courtesy of FORD MOTOR CO.
    NOTE: Coat the valve tappets with clean engine oil prior to installation.
  45. Install the valve tappets,
    46. CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  46. Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3 stages:
    • Stage 1: Tighten the camshaft bearing cap bolts until finger tight.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (12 lb-ft).
    47. Fig 43: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts
    GF0028728Courtesy of FORD MOTOR CO.
  47. Install the variable camshaft timing (VCT) solenoid and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    48. Fig 44: Locating Variable Camshaft Timing (VCT) Solenoid And Bolt
    GF0028851Courtesy of FORD MOTOR CO.
    NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
  48. Install the crankshaft sprocket and crankshaft sprocket diamond washers.
    • The crankshaft sprocket flange must be facing away from the engine block.
    49. Fig 45: Locating Washers, Oil Pump Chain & Sprockets
    GF0009076Courtesy of FORD MOTOR CO.
  49. Install the oil pump drive chain, sprocket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
    50. Fig 46: Locating Oil Pump Chain, Sprocket & Bolt
    GF0024203Courtesy of FORD MOTOR CO.

    Late build vehicles 

  50. Install the oil pump drive chain tensioner shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
    51. Fig 47: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
    GF0009078Courtesy of FORD MOTOR CO.

    Early build vehicles 

  51. Install the oil pump drive chain guide and the shoulder bolts.
    • Tighten to 10 Nm (89 lb-in).
    52. Fig 48: Locating Oil Pump Chain Guide & Shoulder Bolts
    GF0024102Courtesy of FORD MOTOR CO.

    All vehicles 

  52. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
    53. Fig 49: Locating Oil Pump Chain Tensioner And Bolt
    GF0024103Courtesy of FORD MOTOR CO.
    CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  53. Install the special tool in the slots on the rear of both camshafts.
    54. Fig 50: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  54. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    55. Fig 51: Locating Camshaft Sprockets And Bolts
    GF0028721Courtesy of FORD MOTOR CO.
  55. Install the timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    56. Fig 52: Identifying Bolts And LH Timing Chain Guide
    G03897780Courtesy of FORD MOTOR CO.
  56. Install the timing chain.
    57. Fig 53: Locating Timing Chain
    GF0028718Courtesy of FORD MOTOR CO.
  57. Install the timing chain tensioner arm.
    58. Fig 54: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
    CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
  58. Using the edge of a vise, compress the timing chain tensioner plunger.
    59. Fig 55: Using Edge Of A Vise To Compress Timing Chain Tensioner Plunger
    GF0009079Courtesy of FORD MOTOR CO.
  59. Using a small pick, push back and hold the ratchet mechanism.
    60. Fig 56: Using A Small Pick To Push Back And Hold Ratchet Mechanism
    GF0009080Courtesy of FORD MOTOR CO.
  60. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    61. Fig 57: Pushing Ratchet Arm Back Into Tensioner Housing
    GF0009081Courtesy of FORD MOTOR CO.
  61. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    62. Fig 58: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet Assembly And Plunger
    GF0009082Courtesy of FORD MOTOR CO.
  62. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
    63. Fig 59: Locating Timing Chain Tensioner Bolts And Paper Clip
    GF0024080Courtesy of FORD MOTOR CO.
    CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  63. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • Tighten to 72 Nm (53 lb-ft).
    64. Fig 60: Identifying Camshafts Sprocket Bolts
    GF0028722Courtesy of FORD MOTOR CO.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  64. Clean and inspect the mounting surfaces of the engine and the front cover.
    65. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
  65. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
    66. Fig 61: Locating Silicone Gasket
    G03897744Courtesy of FORD MOTOR CO.
  66. Install the engine front cover. Tighten the 22 bolts in the sequence shown, to the following specifications:
    • Tighten the 8-mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
    67. Fig 62: Identifying Engine Front Cover Bolts Tightening Sequence
    GF0024077Courtesy of FORD MOTOR CO.
    NOTE: Remove the through-bolt from the special tool.
    NOTE: Lubricate the oil seal with clean engine oil.
  67. Using the special tool, install a new crankshaft front oil seal.
    68. Fig 63: Installing Crankshaft Front Oil Seal Using Special Tool
    G03897717Courtesy of FORD MOTOR CO.
    CAUTION: Do not install the crankshaft pulley bolt at this time.
    NOTE: Apply clean engine oil on the seal area before installing.
  68. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    69. Fig 64: Locating Crankshaft Pulley & Hole
    GF0008924Courtesy of FORD MOTOR CO.
    CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
  69. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
    70. Fig 65: Locating Crankshaft Pulley Bolt
    GF0008925Courtesy of FORD MOTOR CO.
  70. Assemble the special tools using 4 hardened washers in the locations shown.
    71. Fig 66: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
    GF0024071Courtesy of FORD MOTOR CO.
    CAUTION: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.
    CAUTION: Do not reuse the crankshaft pulley bolt.
  71. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
    72. Fig 67: Using Special Tools (205-126, 205-072-02) To Hold Crankshaft Pulley In Place
    GF0028858Courtesy of FORD MOTOR CO.
  72. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    73. Fig 68: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  73. Remove the special tool.
    74. Fig 69: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  74. Remove the special tool.
    75. Fig 70: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    NOTE: Only turn the engine in the normal direction of rotation.
  75. Turn the crankshaft clockwise 1 and 3/4 turns.
  76. Install the special tool.
    77. Fig 71: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
    NOTE: Only turn the engine in the normal direction of rotation.
  77. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
    78. Fig 72: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
    CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
  78. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected.
    79. Fig 73: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  79. Using the special tool, check the position of the camshafts.
    • If it is not possible to install the special tool, the engine valve timing must be corrected.
    80. Fig 74: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  80. Remove the special tool.
    81. Fig 75: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
  81. Install a new CKP sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
    82. Fig 76: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
    NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.
  82. Adjust the CKP sensor with the alignment tool.
    • Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
    83. Fig 77: Locating CKP Sensor Alignment Tool And Bolts
    GF0009614Courtesy of FORD MOTOR CO.
  83. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    84. Fig 78: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  84. Remove the special tool.
    85. Fig 79: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  85. Install the engine plug bolt.
    • Tighten to 20 Nm (15 lb-ft).
    86. Fig 80: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
  86. Clean the valve cover gasket surface with metal surface cleaner.
    87. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
  87. Apply silicone gasket and sealant to the locations shown.
    88. Fig 81: Applying Silicone Gasket And Sealant
    GF0028709Courtesy of FORD MOTOR CO.
  88. Install the valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
    89. Fig 82: Identifying Valve Cover Bolts Tightening Sequence
    GF0028710Courtesy of FORD MOTOR CO.
    NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.
  89. Install the oil level indicator.
    90. Fig 83: Locating Oil Level Indicator
    GF0028711Courtesy of FORD MOTOR CO.
    NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
  90. Install the 4 coil-on-plug assemblies 4 bolts.
    • Tighten to 8 Nm (71 lb-in).
    91. Fig 84: Locating Coil-On-Plug Assemblies And Bolts
    GF0028849Courtesy of FORD MOTOR CO.
    CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
  91. Install new fuel injector O-rings.
    • Separate the fuel injectors from the fuel rail.
    • Remove and discard the fuel injector O-rings.
    • Install new O-rings and lubricate with clean engine oil.
    • Install the fuel injectors onto the fuel rail.
    92. Fig 85: Identifying Fuel Injector O-Ring Seals
    GF0000307Courtesy of FORD MOTOR CO.
  92. Install the fuel rail and injector assembly and the 2 bolts.
    • Tighten to 23 Nm (17 lb-ft).
    93. Fig 86: Locating Fuel Rail And Injector Assembly Bolts
    GF0028848Courtesy of FORD MOTOR CO.
    NOTE: Typical wiring harness retainers shown.
  93. Position the wiring harness on the engine and attach the wiring harness retainers.
    94. Fig 87: Locating Wiring Harness Retainers
    GF0028847Courtesy of FORD MOTOR CO.
  94. Connect the 4 fuel injector electrical connectors.
    95. Fig 88: Locating Fuel Injector Electrical Connectors
    GF0028846Courtesy of FORD MOTOR CO.
  95. Install the fuel supply rail insulator and attach the 2 pin-type harness retainers.
    96. Fig 89: Locating Pin-Type Harness Retainers And Remove Fuel Supply Rail Insulator
    GF0028845Courtesy of FORD MOTOR CO.
  96. Connect the cylinder head temperature (CHT) sensor electrical connector and install the boot.
    97. Fig 90: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector And Boot
    GF0028844Courtesy of FORD MOTOR CO.
  97. Connect the 4 coil-on-plug electrical connectors.
    98. Fig 91: Locating Coil-On-Plug Electrical Connectors
    GF0028843Courtesy of FORD MOTOR CO.
  98. Connect the VCT solenoid electrical connector.
    99. Fig 92: Locating Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    GF0028842Courtesy of FORD MOTOR CO.
  99. Connect the camshaft position (CMP) sensor electrical connector.
    100. Fig 93: Locating Camshaft Position (CMP) Sensor Electrical Connector
    GF0028841Courtesy of FORD MOTOR CO.
  100. Install a new gasket, the oil filter adapter and the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    101. Fig 94: Locating Oil Filter Adapter And Bolts
    GF0028840Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the oil filter seal (spin on filter type) or oil filter cup O-ring seal (replaceable filter element type) with clean engine oil.
  101. Install a new engine oil filter.
    • Tighten the oil filter (spin on filter type) to 18 Nm (13 lb-ft).
    • Tighten the oil filter cup (replaceable filter element type) to 33 Nm (24 lb-ft).
  102. Using a new gasket, install the crankcase vent oil separator and the bolts.
    • Tighten to 10 Nm (89 lb-in).
    103. Fig 95: Locating Crankcase Vent Oil Separator And Bolts
    GF0024189Courtesy of FORD MOTOR CO.
    NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
  103. Install the KS and the bolt.
    • Tighten to 20 Nm (15 lb-ft).
    104. Fig 96: Locating Knock Sensor Bolt
    GF0024188Courtesy of FORD MOTOR CO.
  104. Position the bypass hose on the engine and connect the bypass hose to the coolant outlet.
    105. Fig 97: Locating Bypass Hose To Coolant Outlet
    GF0028839Courtesy of FORD MOTOR CO.
  105. Connect the bypass hose to the cylinder block nipple.
    106. Fig 98: Locating Bypass Hose From Cylinder Block Nipple
    GF0024185Courtesy of FORD MOTOR CO.
    NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.
  106. Install the thermostat housing and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    107. Fig 99: Locating Thermostat Housing Bolts
    GF0028838Courtesy of FORD MOTOR CO.
  107. Install the EGR tube.
    • Tighten to 55 Nm (41 lb-ft).
    108. Fig 100: Locating Exhaust Gas Recirculation (EGR) Tube
    GF0024177Courtesy of FORD MOTOR CO.
  108. Position the intake manifold and connect the positive crankcase ventilation hose.
    109. Fig 101: Locating Positive Crankcase Ventilation (PCV) Hose
    GF0024176Courtesy of FORD MOTOR CO.
  109. Install new gaskets, the intake manifold and the 8 bolts.
    • Tighten the bolts to 18 Nm (13 lb-ft).
    110. Fig 102: Locating Intake Manifold Bolts
    GF0028837Courtesy of FORD MOTOR CO.
  110. Connect the electronic throttle body electrical connector.
    111. Fig 103: Locating Electronic Throttle Body Electrical Connector
    GF0028836Courtesy of FORD MOTOR CO.
  111. Attach the 2 wiring harness pin-type retainers to the intake manifold.
    112. Fig 104: Locating Wiring Harness Pin-Type Retainers From Intake Manifold
    GF0028835Courtesy of FORD MOTOR CO.
  112. Connect the 2 swirl control valve electrical connectors.
    113. Fig 105: Locating Swirl Control Valve Electrical Connectors
    GF0028834Courtesy of FORD MOTOR CO.
  113. Connect the intake manifold runner control (IMRC) actuator electrical connector.
    114. Fig 106: Locating Intake Manifold Runner Control (IMRC) Actuator Electrical Connector
    GF0028833Courtesy of FORD MOTOR CO.
  114. Connect the temperature manifold actual pressure (MAP) sensor electrical connector.
    115. Fig 107: Locating Manifold Actual Pressure (MAP) Sensor Electrical Connector
    GF0024170Courtesy of FORD MOTOR CO.
  115. Connect the oil pressure sender electrical connector.
    116. Fig 108: Locating Oil Pressure Sender Electrical Connector
    GF0028832Courtesy of FORD MOTOR CO.
  116. Connect the exhaust gas recirculation (EGR) coolant hose and electrical connector.
    117. Fig 109: Locating Exhaust Gas Recirculation (EGR) Coolant Hose And Electrical Connector
    GF0028831Courtesy of FORD MOTOR CO.
  117. Connect the coolant temperature sender electrical connector.
    118. Fig 110: Locating Coolant Temperature Sender Electrical Connector
    GF0028830Courtesy of FORD MOTOR CO.
  118. Install the catalytic converter bracket and the 2 bolts.
    • Tighten to 35 Nm (26 lb-ft).
    119. Fig 111: Locating Catalytic Converter Bracket Bolts
    GF0028829Courtesy of FORD MOTOR CO.
  119. If equipped, install the block heater.
    • Tighten to 21 Nm (15 lb-ft).
    120. Fig 112: Locating Block Heater
    GF0028828Courtesy of FORD MOTOR CO.
  120. If equipped, connect the block heater electrical connector.
    121. Fig 113: Locating Block Heater Electrical Connector
    GF0028827Courtesy of FORD MOTOR CO.
  121. Install 7 new catalytic converter studs in the cylinder head.
    • Tighten to 17 Nm (13 lb-ft).
    122. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
    CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
    NOTE: Make sure to tighten the nuts in the sequence in 2 stages.
  122. Install a new gasket, the catalytic converter and 7 new nuts. Tighten the nuts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 55 Nm (41 lb-ft).
    • Stage 2: Tighten to 55 Nm (41 lb-ft).
    123. Fig 114: Identifying Catalytic Converter Manifold Nuts Tightening Sequence
    GF0025494Courtesy of FORD MOTOR CO.
  123. Install the 2 catalytic converter bracket bolts.
    • Tighten to 20 Nm (15 lb-ft).
    124. Fig 115: Locating Catalytic Converter Bracket Bolts
    GF0028825Courtesy of FORD MOTOR CO.
    NOTE: Vehicles equipped with AIR did not require removal of the heat shield.
  124. Install the heat shield and the 6 screws.
    • Tighten to 10 Nm (89 lb-in).
    125. Fig 116: Locating Heat Shield Screws
    GF0028824Courtesy of FORD MOTOR CO.
  125. Attach the wiring harness retainer to the valve cover stud.
    126. Fig 117: Locating Wiring Harness Retainer
    GF0028823Courtesy of FORD MOTOR CO.
  126. Attach the wiring harness bracket to the valve cover stud.
    127. Fig 118: Locating Wiring Harness Bracket
    GF0028822Courtesy of FORD MOTOR CO.
  127. Connect the heated oxygen sensor (HO2S) electrical connector.
    128. Fig 119: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0028821Courtesy of FORD MOTOR CO.
    NOTE: Vehicles equipped with secondary air injection (AIR) have 2 catalyst monitor sensors (CMS).
  128. Connect the CMS electrical connector(s).
    129. Fig 120: Locating CMS Electrical Connector
    GF0028820Courtesy of FORD MOTOR CO.

    Vehicles with secondary air injection (AIR) 

  129. Position the AIR valve, hoses and pump assembly onto the engine and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    130. Fig 121: Locating Pump Assembly Bolts
    GF0028819Courtesy of FORD MOTOR CO.
  130. Connect the AIR valve electrical connector.
    131. Fig 122: Locating AIR Valve Electrical Connector
    GF0028818Courtesy of FORD MOTOR CO.
  131. Connect the AIR valve vacuum supply tube to the intake manifold.
    132. Fig 123: Locating AIR Valve Vacuum Supply Tube
    GF0028817Courtesy of FORD MOTOR CO.
  132. Connect the AIR hose to the catalytic converter.
    133. Fig 124: Locating Secondary AIR Injection (AIR) Hose
    GF0028816Courtesy of FORD MOTOR CO.

    All vehicles 

  133. Install the generator, bolt and 2 stud bolts.
    • Tighten to 47 Nm (35 lb-ft).
    134. Fig 125: Locating Generator Bolt And Stud Bolts
    GF0028815Courtesy of FORD MOTOR CO.
  134. Connect the pin-type retainer, generator electrical connections and install the nut.
    • Tighten to 6 Nm (53 lb-in).
    • Install the rubber boot.
    135. Fig 126: Locating Pin-Type Retainer And Generator Electrical Connections
    GF0028814Courtesy of FORD MOTOR CO.
  135. Install the generator splash shield and the 2 nuts.
    • Tighten to 25 Nm (18 lb-ft).
    136. Fig 127: Locating Generator Splash Shield And Nuts
    GF0028813Courtesy of FORD MOTOR CO.
  136. Connect the CKP sensor electrical connector and harness pin-type retainer.
    137. Fig 128: Locating Crankshaft Position (CKP) Sensor Electrical Connector And Harness Pin-Type Retainer
    GF0028811Courtesy of FORD MOTOR CO.
  137. Install the accessory drive belt idler pulley.
    • Tighten to 25 Nm (18 lb-ft).
    138. Fig 129: Locating Accessory Drive Belt Idler Pulley Bolt
    GF0028810Courtesy of FORD MOTOR CO.
    NOTE: Clean the coolant pump mating surface with metal surface cleaner.
    NOTE: Lubricate the new coolant pump O-ring with clean engine coolant.
  138. Install the new O-ring, coolant pump and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    139. Fig 130: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
  139. Install the coolant pump pulley and the 3 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    140. Fig 131: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  140. Install the A/C compressor and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    141. Fig 132: Locating A/C Compressor Bolts
    GF0028809Courtesy of FORD MOTOR CO.
  141. Install the A/C manifold and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    142. Fig 133: Locating A/C Manifold And Bolt
    GF0028808Courtesy of FORD MOTOR CO.
  142. Connect the A/C compressor electrical connector.
    143. Fig 134: Locating A/C Compressor Electrical Connector
    GF0028807Courtesy of FORD MOTOR CO.
  143. Position the coolant hose on the engine and connect the coolant hose to the throttle body.
    144. Fig 135: Locating Coolant Hose
    GF0028806Courtesy of FORD MOTOR CO.
  144. Connect the lower radiator and heater hoses to the thermostat housing.
    145. Fig 136: Locating Lower Radiator And Heater Hoses From Thermostat Housing
    GF0028805Courtesy of FORD MOTOR CO.
  145. Connect the KS electrical connector and the 2 harness pin-type retainers.
    146. Fig 137: Locating Knock Sensor (KS) Electrical Connector And Harness Pin-Type Retainers
    GF0028804Courtesy of FORD MOTOR CO.
  146. Install the power steering pump and the lower bolt.
    • Finger tighten the bolt.
    147. Fig 138: Locating Power Steering Pump And Lower Bolt
    GF0028803Courtesy of FORD MOTOR CO.
  147. Install the 2 upper power steering pump bolts.
    • Tighten all 3 power steering bolts to 25 Nm (18 lb-ft).
    148. Fig 139: Locating Upper Power Steering Pump Bolts
    GF0028802Courtesy of FORD MOTOR CO.
  148. Connect the power steering pressure (PSP) switch electrical connector.
    149. Fig 140: Locating Power Steering Pressure (PSP) Switch Electrical Connector
    GF0028801Courtesy of FORD MOTOR CO.
  149. Install the accessory drive belt tensioner and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    150. Fig 141: Locating Accessory Drive Belt Tensioner Bolts
    GF0028800Courtesy of FORD MOTOR CO.
  150. Position the accessory drive belt onto the tensioner and all of the accessory drive pulleys except the coolant pump pulley.
  151. Using the hex feature, rotate the accessory drive belt tensioner clockwise and install the accessory drive belt onto the coolant pump pulley.
    152. Fig 142: Rotating Accessory Drive Belt Tensioner Clockwise
    GF0024456Courtesy of FORD MOTOR CO.
  152. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.

    153. Vehicles with automatic transaxle 

  153. Install the flexplate and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
    • Stage 3: Tighten to 112 Nm (83 lb-ft).
    154. Fig 143: Identifying Flexplate Bolts Tightening Sequence
    GF0024206Courtesy of FORD MOTOR CO.

    Vehicles with manual transaxle 

  154. Install the flywheel and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
    • Stage 3: Tighten to 112 Nm (83 lb-ft).
    155. Fig 144: Identifying Flexplate Bolts Tightening Sequence
    G03897718Courtesy of FORD MOTOR CO.
  155. Install the starter motor isolator.
    156. Fig 145: Locating Starter Motor Isolator
    GF0024150Courtesy of FORD MOTOR CO.
  156. Lubricate the transaxle input shaft pilot bearing with front axle grease.
    157. Fig 146: Lubricating Transaxle Input Shaft Pilot Bearing With Front Axle Grease
    GF0009091Courtesy of FORD MOTOR CO.
  157. Using the special tool, position the clutch disc on the flywheel.
    158. Fig 147: Positioning Clutch Disc On Flywheel Using Special Tool (308-006)
    GF0024207Courtesy of FORD MOTOR CO.
    NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
  158. Position the clutch pressure plate and install the 6 bolts.
    • Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.
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