Intake Manifold

Fig 1: Exploded View Of Intake Manifold

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	9288	Fuel supply tube
2	8K556	Coolant outlet
3	9D475	EGR valve
4	9E926	Throttle Body (TB)
5	6051	Cylinder head gasket
6	6010	Cylinder block
7	12A699	Knock Sensor (KS)
8	6754	Oil level indicator and tube
9	9424	Intake manifold
10	9439	Intake manifold gasket
11	6049	Cylinder head
12	9F593	Fuel injector (4 required)
13	9H487	Fuel rail

NOTE: 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 the pulley bolt is loosened. 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.

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: 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 .

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 2: Locating Oil Squirters
  Courtesy of FORD MOTOR CO.
Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.

Fig 3: Identifying Crankshaft Main Bearing Journal Diameter Measuring Directions
Courtesy of FORD MOTOR CO.
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 4: Locating Main Bearing Beam In Engine Block
Courtesy of FORD MOTOR CO.
Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
- Tighten the bolts in the sequence shown in illustration 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 5: Identifying Main Bearing Beam Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Measure each crankshaft block housing main bearing bore diameter.
- Remove the bolts and the main bearing beam.
- Discard the main bearing beam bolts.
  
  Fig 6: Identifying Crankshaft Block Housing Main Bearing Bore Diameter
  Courtesy of FORD MOTOR CO.
Using the chart, select the crankshaft main bearings.

Fig 7: Crankshaft Main Bearings Chart
Courtesy of FORD MOTOR CO.

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.
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 8: Identifying Connecting Rod Large End Bore Measuring Directions
  Courtesy of FORD MOTOR CO.
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 9: Locating Crankshaft Connecting Rod Bearing Journal Diameters In Measuring Directions
Courtesy of FORD MOTOR CO.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

Fig 10: Connecting Rod Bearings Chart
Courtesy of FORD MOTOR CO.

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.

Fig 11: Locating Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

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

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

Fig 12: Locating Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.

Fig 13: Locating Crankshaft Of Engine Block
Courtesy of FORD MOTOR CO.
Lubricate the 10 main bearing beam side fit surfaces (front 2 shown in illustration) with clean engine oil.

Fig 14: Locating Main Bearing Beam Lubrication Area
Courtesy of FORD MOTOR CO.
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 15: Locating Main Bearing Beam In Engine Block
Courtesy of FORD MOTOR CO.

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 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 16: Identifying Main Bearing Beam Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
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 17: Measuring Crankshaft End Play Using Dial Indicator Gauge With Holding Fixture
  Courtesy of FORD MOTOR CO.

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 18: Identifying Piston Ring Compressor And Connecting Rod Installer
  Courtesy of FORD MOTOR CO.

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 bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 19: Locating Connecting Rod Caps And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: 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.

Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).

NOTE: The Crankshaft TDC Timing Peg 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.

Fig 20: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Install the Crankshaft TDC Timing Peg.

NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.

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 (177 lb-in).
  
  Fig 21: Identifying Oil Pump Assembly Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Using a new oil pump pickup tube gasket, install the pickup tube and bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 22: Locating Bolts, Oil Pump Pickup Tube And Gasket
  Courtesy of FORD MOTOR CO.
Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear seal.

Fig 23: Identifying Crankshaft Rear Main Oil Seal Installer
Courtesy of FORD MOTOR CO.
Tighten the 6 crankshaft rear seal with retainer plate bolts in the sequence shown in illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 24: Identifying Crankshaft Rear Oil Seal Retainer Plate Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

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, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

Clean and inspect all mating surfaces.

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 prep. 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.

Fig 25: Locating Oil Pan Silicone Gasket And Sealant Bead Applying Area

Courtesy of FORD MOTOR CO.

Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
Install the oil pan. Install the 2 oil pan bolts finger-tight.

Fig 26: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.

Fig 27: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block Using Straightedge
Courtesy of FORD MOTOR CO.
Install the remaining 13 oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration to 25 Nm (18 lb-ft).

Fig 28: Identifying Oil Pan Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.

Fig 29: Locating Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
Apply silicone gasket and sealant to the locations shown in illustration.

Fig 30: Locating Sealant Applying Area On Cylinder Block
Courtesy of FORD MOTOR CO.
Install a new cylinder head gasket.

Fig 31: Locating Cylinder Head Gasket
Courtesy 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.

Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Turn 90 degrees.
- Stage 5: Turn an additional 90 degrees.
  
  Fig 32: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: If the camshafts and valve tappets are to be reused, make sure they are assembled in their original positions.

NOTE: Coat the valve tappets with clean engine oil.

Install the valve tappets.

NOTE: 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 disassembly 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.

Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
- Stage 1: Tighten one turn at a time until tight.
- Stage 2: Tighten to 7 Nm (62 lb-in).
- Stage 3: Tighten to 16 Nm (142 lb-in).
  
  Fig 33: Identifying Camshafts And Bearing Caps Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.

Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
- The crankshaft sprocket flange must be facing away from the engine block.
  
  Fig 34: Locating Crankshaft Sprocket Flange
  Courtesy of FORD MOTOR CO.
Install the oil pump chain, sprocket and bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 35: Locating Oil Pump Chain, Sprocket And Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump chain tensioner shoulder bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 36: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 37: Locating Oil Pump Chain Tensioner
  Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Fig 38: Checking Position Of Camshafts Using Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.

Fig 39: Locating Camshaft Sprockets And Bolts
Courtesy of FORD MOTOR CO.
Install the LH timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 40: Locating LH Timing Chain Guide Bolts
  Courtesy of FORD MOTOR CO.
Install the timing chain.

Fig 41: Locating Timing Chain
Courtesy of FORD MOTOR CO.
Install the RH timing chain guide.

Fig 42: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.

NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Fig 43: Compressing Timing Chain Tensioner Plunger

Courtesy of FORD MOTOR CO.

Using the edge of a vise, compress the timing chain tensioner plunger.
Using a small pick, push back and hold the ratchet mechanism.

Fig 44: Holding Ratchet Mechanism Using Small Pick
Courtesy of FORD MOTOR CO.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 45: Pushing Ratchet Arm Back Into Tensioner Housing
Courtesy of FORD MOTOR CO.
Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

Fig 46: Holding Ratchet Assembly Using Paper Clip
Courtesy of FORD MOTOR CO.
Install the timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the paper clip to release the piston.
  
  Fig 47: Locating Timing Chain Tensioner And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Fig 48: Locating Camshaft Drive Gear Bolts

Courtesy of FORD MOTOR CO.

Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts to 72 Nm (53 lb-ft).

NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the mounting surfaces of the engine and the front cover.

NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.

Fig 49: Locating Bead Of Silicone Gasket And Sealant Applying Area On Front Cover

Courtesy of FORD MOTOR CO.

Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
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).
  
  Fig 50: Identifying Engine Front Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.

Fig 51: Installing Crankshaft Front Oil Seal Using Camshaft Front Oil Seal Installer

Courtesy of FORD MOTOR CO.

Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.

NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

Fig 52: Locating Crankshaft Pulley Position

Courtesy of FORD MOTOR CO.

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.

NOTE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Fig 53: Locating Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.

NOTE: The crankshaft must remain in the Top Dead Center (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 Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).
- Stage 2: Tighten an additional 90 degrees (one-fourth turn).
  
  Fig 54: Locating Crankshaft Pulley Bolt And Washer
  Courtesy of FORD MOTOR CO.
Remove the 6 mm x 18 mm bolt.

Fig 55: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the Crankshaft TDC Timing Peg.

Fig 56: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Remove the Camshaft Alignment Plate.

Fig 57: Checking Position Of Camshafts Using Camshaft Alignment Plate
Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise one and three-fourths turn.
Install the Crankshaft TDC Timing Peg.

Fig 58: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

Fig 59: Identifying Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.

NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, the engine valve timing must be corrected.
  
  Fig 60: Locating Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.
Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
  
  Fig 61: Checking Position Of Camshafts Using Camshaft Alignment Plate
  Courtesy of FORD MOTOR CO.
Remove the Camshaft Alignment Plate.

Fig 62: Checking Position Of Camshafts Using Camshaft Alignment Plate
Courtesy of FORD MOTOR CO.
Install the Crankshaft Position (CKP) sensor and the 2 bolts.
- Do not tighten the bolts at this time.
  
  Fig 63: Locating CKP Sensor Bolts
  Courtesy of FORD MOTOR CO.
Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
- Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
  
  Fig 64: Adjusting CKP Sensor Using Crankshaft Sensor Aligner
  Courtesy of FORD MOTOR CO.
Remove the 6 mm x 18 mm bolt.

Fig 65: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the Crankshaft TDC Timing Peg.

Fig 66: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 67: Locating Engine Plug Bolt
  Courtesy of FORD MOTOR CO.

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 which make leak paths.

Clean the valve cover gasket surface with metal surface prep.
Apply silicone gasket and sealant to the locations shown in illustration.

Fig 68: Locating Sealant Applying Area On Valve Cover
Courtesy of FORD MOTOR CO.

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 prep.

Install the valve cover.
- Tighten the 14 bolts in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 69: Identifying Valve Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.

Install the Cylinder Head Temperature (CHT) sensor and the spark plugs.
- Tighten the CHT sensor to 12 Nm (106 lb-in).
- Tighten the spark plugs to 12 Nm (106 lb-in).
  
  Fig 70: Locating Cylinder Head Temperature Sensor And Spark Plug
  Courtesy of FORD MOTOR CO.

NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the 4 ignition coil-on-plugs and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 71: Locating Ignition Coil-On-Plug Bolts
  Courtesy of FORD MOTOR CO.
Install the intermediate shaft bracket and the 3 bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 72: Locating Intermediate Shaft Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 73: Locating Crankcase Vent Oil Separator Mounting Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.

Install the KS and the bolt.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 74: Locating Bolt And Knock Sensor
  Courtesy of FORD MOTOR CO.
Install the A/C compressor, 2 bolts and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 75: Locating A/C Compressor, Stud Bolts And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.

Install the thermostat housing and 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 76: Locating Thermostat Housing And Bolts
  Courtesy of FORD MOTOR CO.
Connect the coolant bypass hose.

Fig 77: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
Using a new gasket, install the coolant outlet and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 78: Locating Coolant Outlet Bolts
  Courtesy of FORD MOTOR CO.
Connect the coolant bypass hose.

Fig 79: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
Install the radio interference capacitor bracket and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 80: Locating Radio Interference Capacitor Bracket With Bolt
  Courtesy of FORD MOTOR CO.
Install the EGR tube.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 81: Identifying Exhaust Gas Recirculation Tube
  Courtesy of FORD MOTOR CO.
Inspect and install new intake manifold gaskets if necessary.

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.

Fig 82: Locating PCV Hose Connector

Courtesy of FORD MOTOR CO.

Position the intake manifold and connect the PCV hose.

NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash bracket to the intake manifold. The 2 bolts are equipped with an attachment feature that allows them to be loosened but remain attached to the intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.

Fig 83: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

Install the intake manifold and hand-tighten the 2 intake manifold bolts.
Install the 5 intake manifold mounting bolts.
- Tighten all 7 bolts to 18 Nm (159 lb-in).
  
  Fig 84: Locating Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new O-ring with clean engine oil.

Using a new O-ring seal, install the oil level indicator tube assembly and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 85: Locating Oil Level Indicator Tube Bolt
  Courtesy of FORD MOTOR CO.
Install the lower intake manifold bolt.
- Tighten to 18 Nm (159 lb-in).
  
  Fig 86: Identifying Lower Intake Manifold Bolt
  Courtesy of FORD MOTOR CO.
Connect the EGR valve electrical connector.

Fig 87: Locating EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
- Attach the 3 wiring harness retainers to the intake manifold.
  
  Fig 88: Locating Wiring Harness Retainers To Intake Manifold
  Courtesy of FORD MOTOR CO.
Connect the throttle control electrical connector.

Fig 89: Locating Throttle Control Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the KS electrical connector and pin-type retainer.

Fig 90: Locating Knock Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.

NOTE: 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.

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.
  
  Fig 91: Locating Fuel Injector O-Rings
  Courtesy of FORD MOTOR CO.
Install the fuel rail with the fuel injectors and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 92: Locating Fuel Rail Bolts
  Courtesy of FORD MOTOR CO.
Connect the 4 fuel injector electrical connectors and attach the 4 wiring harness retainers to valve cover stud bolts and intake manifold.

Fig 93: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer on the valve cover stud.

Fig 94: Locating Wiring Harness Retainer On Valve Cover Stud
Courtesy of FORD MOTOR CO.
Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.

Fig 95: Locating Cylinder Head Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.

Fig 96: Locating Coil-On-Plug And Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.

NOTE: Clean the gasket mating surfaces with metal surface prep.

Using a new gasket, install the oil filter adapter and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 97: Locating Oil Filter Adapter And 4 Bolts
  Courtesy of FORD MOTOR CO.

NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

Install a new oil cooler and bolt.
- Tighten to 34 Nm (25 lb-ft).
  
  Fig 98: Locating Oil Cooler And Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the oil filter gasket with clean engine with clean engine oil prior to installation.

Install the oil filter.
- Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
  
  Fig 99: Locating Oil Filter
  Courtesy of FORD MOTOR CO.
Connect the oil cooler hoses.

Fig 100: Locating Oil Cooler Hoses
Courtesy of FORD MOTOR CO.
Connect the Engine Oil Pressure (EOP) switch electrical connector.

Fig 101: Locating Engine Oil Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the EGR valve coolant hose.

Fig 102: Locating Coolant Hose Of EGR Valve
Courtesy of FORD MOTOR CO.
Connect the oil cooler hose and lower radiator hose to the thermostat housing.

Fig 103: Locating Oil Cooler Hose And Lower Radiator Hose From Thermostat Housing
Courtesy of FORD MOTOR CO.

NOTE: Clean the coolant pump mating surface with metal surface prep.

NOTE: Lubricate the coolant pump O-ring with clean engine coolant.

Position the coolant pump and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 104: Locating Coolant Pump And Bolts
  Courtesy of FORD MOTOR CO.
Install the coolant pump pulley and 3 bolts.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 105: Locating Coolant Pump Pulley Bolts
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 106: Locating Accessory Drive Belt Idler Pulley And Bolt
  Courtesy of FORD MOTOR CO.
Using the Floor Crane and Spreader Bar, remove the engine from the engine stand.
Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (50 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).
  
  Fig 107: Identifying Flexplate Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.