Part 2
EngineAssembly (Steps 27-84)
27. Install the RH secondary timing chain tensioner and the 2 bolts.
^ Tighten to 10 Nm (89 lb-inch).
28. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the RH camshafts to the top dead center (TDC) position and install the special tool on the flats of the camshafts.
29. Assemble the RH variable camshaft timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
^ Align the colored links with the timing marks.
30. Position the RH secondary timing assembly onto the camshafts.
31. Install 2 new bolts and the original washer.
Tighten in 4 stages.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 10 Nm (89 lb-inch).
^ Stage 4: Tighten 90 degrees.
32. Remove the lockpin from the RH secondary timing chain tensioner.
33. Install the LH secondary timing chain tensioner and the 2 bolts.
^ Tighten to 10 Nm (89 lb-inch).
34. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the LH camshafts to the TDC position and install the special tool on the flats of the camshafts.
35. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
^ Align the colored links with the timing marks.
36. Position the LH secondary timing assembly onto the camshafts.
37. Install 2 new bolts and the original washer.
Tighten in 4 stages.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 10 Nm (89 lb-inch).
^ Stage 4: Tighten 90 degrees.
38. Remove the lockpin from the LH secondary timing chain tensioner.
39. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
40. Install the crankshaft timing chain sprocket.
41. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
42. Install the upper LH primary timing chain guide and the 2 bolts.
^ Tighten to 10 Nm (89 lb-inch).
43. Install the lower LH primary timing chain guide and the 2 bolts.
^ Tighten to 10 Nm (89 lb-inch).
44. Install the primary timing chain tensioner arm.
45. Reset the primary timing chain tensioner.
^ Rotate the lever counterclockwise.
^ Using a soft-jawed vise, compress the plunger.
^ Align the hole in the lever with the hole in the tensioner housing.
^ Install a suitable lockpin.
46. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
Install the primary tensioner and the 2 bolts.
^ Tighten to 10 Nm (89 lb-inch).
^ Remove the lockpin.
47. As a post-check, verify correct alignment of all timing marks.
48. Install new VCT housing seals.
49. CAUTION: Make sure the dowels on the variable camshaft timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
Install the LH VCT housing and the 3 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-inch).
50. CAUTION: Make sure the dowels on the variable camshaft timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
Install the RH VCT housing and the 3 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-inch).
51. Install the special tools.
52. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 inch) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
^ Apply a 5.5 mm (0.21 inch) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
53. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 17, 18, 19 and 20.
^ Tighten in sequence to 3 Nm (27 lb-inch).
54. Remove the special tools (alignment pins).
55. NOTE: Do not tighten the bolts at this time.
Install the engine mount bracket and the 3 bolts.
56. CAUTION: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
^ Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-inch) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft).
^ Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
57. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 lb-ft).
58. Install the engine mount bracket and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).
59. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the special tools, install a new crankshaft front seal.
60. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the special tools, install the crankshaft pulley.
61. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 (lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.
62. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
NOTE: Spark plug tube seal installation shown, VCT seal installation similar.
Using the special tools, install new VCT solenoid and/or spark plug tube seals.
63. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 inch) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
64. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-inch).
65. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 inch) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
66. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-inch).
67. Install the wiring harness retaining bracket and the 2 nuts.
^ Tighten to 9 Nm (80 lb-inch).
68. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 7 Nm (62 lb-inch).
69. Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts.
^ Tighten the large bolt to 57 Nm (42 lb-ft).
^ Tighten the small bolt to 10 Nm (89 lb-inch).
70. NOTE: Apply pipe sealant with Teflon(R) to the engine oil pressure (EOP) switch threads.
Install the EOP switch.
^ Tighten to 18 Nm (13 lb-ft).
71. Install the crankshaft position (CKP) sensor and install the bolt.
^ Tighten to 10 Nm (89 lb-inch).
72. Install LH camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
73. Install and connect the cylinder head temperature (CHT) sensor jumper harness.
74. Using new gaskets, install the lower intake manifold and the 10 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-inch).
75. Using a new gasket, install the thermostat housing and the 2 bolts.
^ Tighten to 10 Nm (89 lb-inch).
76. CAUTION: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: The upper and lower O-ring seals are not interchangeable.
Install new fuel injector O-ring seals.
^ Remove the retaining clips and separate the fuel injectors from the fuel rail.
^ Remove and discard the O-ring seals.
^ Install new O-ring seals and lubricate with clean engine oil.
^ Install the fuel injectors and the retaining clips onto the fuel rail.
77. Install the fuel rail and injectors as an assembly and install the 4 bolts.
^ Tighten to 10 Nm (89 lb-inch).
All wheel drive (AWD) vehicles
78. Install the catalytic converter bracket and the 2 bolts.
^ Tighten to 40 Nm (30 lb-ft).
All vehicles
79. Install the RH CMP sensor and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
80. Install the engine lifting eye and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).
81. Install the cover and the pin-type retainer.
82. Install the LH cylinder block drain plug.
^ Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
83. Install the RH cylinder block drain plug or, if equipped, the block heater.
^ Tighten to 40 Nm (30 lb-ft).
84. Install 6 new RH exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
