Engine Mechanical: Mechanical: Engine: Assembly: Engine
SPECIAL TOOL(S)
| Piston Ring Compressor 303-D032 (D81L-6002-C) |
|
| Camshaft Bearing Set 303-017 (T65L-6250-A) | |
| Synchronizer Alignment Gauge 303-589 | |
| Installer, Crankshaft Vibration Damper 303-175 (T82L-6316-A) |
|
| Lifting Eyes 303-D030 (D81L-6001-D) or equivalent |
|
| Spreader Bar 303-D089 (D93P-6001-A3) or equivalent | |
| Heavy Duty Floor Crane 014-00072 or equivalent |
MATERIAL
| Item | Specification |
|---|---|
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Synthetic Motor Oil CXO-5W20-LSP12 (Canada); or equivalent | WSS-M2C930-A |
| Gasket Maker TA-16 | WSK-M2G348-A5 |
| Thread Sealant with PTFE TA-24 | WSK-M2G350-A2 |
| Silicone Gasket and Sealant TA-30 | WSE-M4G323-A4 |
Major Upper Engine Components
Cylinder Block - Lower
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.
- Install the crankshaft upper main bearings.
- Position the crankshaft.
- Install the crankshaft rear seal.
- Apply 2 dots of gasket maker between the rear bearing cap and the cylinder block.
- Install the crankshaft lower main bearings.
- Install the 4 main bearing caps.
- Install the 8 main bearing cap bolts in the sequence shown.
- Tighten the bolts in pairs to 80 Nm (59 lb-ft).
- Carry out the crankshaft and crankshaft bearing component tests. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
- If removed, install new camshaft bearings.
- Install the camshaft.
- Install the camshaft thrust plate and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Inspect the camshaft end play. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
- Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly with the timing marks aligned.
- Install the camshaft sprocket bolt.
- Tighten to 63 Nm (46 lb-ft).
- Install the piston and connecting rod assemblies.
- Install the connecting rod bearings.
- Install the connecting rod caps and nuts.
- Tighten the nuts in pairs to 35 Nm (26 lb-ft).
- Install the oil pump and bolt.
- Tighten to 48 Nm (35 lb-ft).
- Install the 12 valve tappets.
- Install the 6 valve tappet guide plates.
- Install the valve tappet guide plate retainer and the 2 bolts.
- Tighten to 12 Nm (9 lb-ft).
- Position new cylinder head gaskets on the engine.
- Position the cylinder heads.
- Install the cylinder head bolts.
- Tighten the bolts in 5 stages in the sequence shown.
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Loosen the bolts 1 full turn.
- Stage 3: Tighten to 30 Nm (22 lb-ft).
- Stage 4: Rotate an additional 90 degrees.
- Stage 5: Rotate an additional 90 degrees.
- Install the oil filter.
- Align the timing marks.
- Install a new engine front cover gasket and the engine front cover.
- Install the engine front cover and coolant pump assembly.
- Apply pipe sealant with Teflon® to the bolts indicated.
- Install the 5 bolts and 5 stud bolts and tighten to 25 Nm (18 lb-ft).
- Apply 4 beads of silicone gasket and sealant.
- Position the oil pan gasket.
- Position the oil pan and hand-start the bolts.
- Tighten the oil pan bolts to 12 Nm (9 lb-ft) in the sequence shown.
- Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
- Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 38 degrees from the centerline of the engine.
- Install the camshaft synchronizer retaining bolt.
- Tighten to 30 Nm (22 lb-ft).
- Install the camshaft position (CMP) sensor and the 2 bolts.
- Tighten to 3 Nm (27 lb-in).
- Apply 4 beads of silicone gasket and sealant.
- Position the intake manifold gaskets and end seals.
- Install the lower intake manifold and the 8 bolts. Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 15 Nm (11 lb-ft).
- Stage 2: Tighten to 32 Nm (24 lb-ft).
- Install the 12 push rods and the 12 rocker arms.
- Tighten to 32 Nm (24 lb-ft).
- Apply a bead of silicone gasket and sealant to the 4 intake-to-cylinder head seams.
- If removed, install the valve cover gaskets.
- Install the LH valve cover.
- Tighten to 12 Nm (9 lb-ft).
- Install the RH valve cover.
- Tighten to 12 Nm (9 lb-ft).
- Position a new exhaust manifold gasket and install the RH exhaust manifold and 6 bolts.
- Tighten in the sequence shown, in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 22 Nm (16 lb-ft).
- Tighten in the sequence shown, in 2 stages:
- Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
- Install the RH spark plug wires and attach the retainers.
- Position a new exhaust manifold gasket and install the LH exhaust manifold, 4 bolts and 2 stud bolts.
- Tighten in the sequence shown, in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 22 Nm (16 lb-ft).
- Tighten in the sequence shown, in 2 stages:
- Install the LH spark plug wires and attach the retainers.
- Coat the sealing surface of the oil level indicator tube with silicone gasket and sealant.
- Install the oil level indicator and tube and nut.
- Tighten to 18 Nm (13 lb-ft).
- Position the engine control sensor wiring harness onto the engine and attach the wiring harness retainers onto the valve cover studs.
- Connect the 6 fuel injector electrical connectors.
- Connect the oil pressure switch electrical connector.
- Connect the camshaft position (CMP) sensor and engine coolant temperature (ECT) sensor electrical connectors.
- Install the upper intake manifold, radio interference capacitor, bolt and 3 stud bolts.
- Tighten the retainers in 2 stages in the sequence shown.
- Stage 1: Tighten the retainers hand tight.
- Stage 2: Tighten the retainers to 10 Nm (89 lb-in).
- Tighten the retainers in 2 stages in the sequence shown.
- Install the EGR vacuum regulator and the 2 nuts.
- Tighten to 6 Nm (53 lb-in).
- Attach the spark plug wire retainer to the intake manifold stud bolt.
- Connect the positive crankcase ventilation (PCV) tube to the PCV valve.
- Connect the PCV tube to the upper intake manifold.
- Connect the intake manifold runner control (IMRC) and PCV electrical connectors.
- Connect the RH heated oxygen sensor (HO2S) electrical connector.
- Connect the vacuum tube and electrical connector to the exhaust gas recirculation (EGR) vacuum regulator.
- Connect the vacuum tube and electrical connector to the fuel rail pressure (FRP) sensor.
- Connect the EGR valve vacuum hose.
- Position the upper intake manifold support bracket and install the bolt and 2 nuts.
- Tighten the bolt to 50 Nm (37 lb-ft).
- Tighten the 2 nuts to 6 Nm (53 lb-in).
- Attach the pin-type harness retainer to the bracket.
- Connect the idle air control (IAC) valve and throttle position (TP) sensor electrical connectors.
- Attach the harness retainer to the throttle body stud bolt.
- Install the EGR tube.
- Tighten to 50 Nm (37 lb-ft).
- Connect the electrical connector.
- Using the special tool, install the crankshaft damper.
- Install the crankshaft damper bolt and the washer.
- Tighten to 145 Nm (107 lb-ft).
- Install the crankshaft position (CKP) sensor and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Install the crankshaft pulley and the bolts.
- Tighten to 63 Nm (46 lb-ft).
- Connect the CKP sensor electrical connector.
- Install the coolant pump pulley and 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Install the RH engine support bracket and the 4 bolts.
- Tighten to 47 Nm (35 lb-ft).
- Install the heat shield and the 2 pin-type retainers.
- Install the knock sensor (KS) and bolt.
- Tighten to 25 Nm (18 lb-ft).
- Connect the KS electrical connector and the 3 wiring harness pin-type retainers.
- Install the A/C compressor mounting bracket and 4 bolts.
- Tighten to 48 Nm (35 lb-ft).
- Install the A/C compressor and 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Install the wiring harness connectors on the bracket and connect the LH heated oxygen sensor (HO2S) electrical connector.
- Connect the A/C compressor clutch coil electrical connector.
- Connect the A/C high pressure cutoff switch electrical connector.
- Install the power steering pump and bracket assembly, bolt and 2 nuts.
- Tighten to 48 Nm (35 lb-ft).
- Install the support bracket, nut and bolt.
- Tighten to 25 Nm (18 lb-ft).
- Install the drive belt tensioner and bolt.
- Tighten to 48 Nm (35 lb-ft).
- Install the drive belt idler pulley and bolt.
- Tighten to 48 Nm (35 lb-ft).
- Install the generator support bracket, generator, nut and the bolt.
- Hand tighten the bolt and the nut.
- Install the engine roll restrictor brace, nut and the bolt.
- Tighten to 48 Nm (35 lb-ft).
- Tighten the generator support bracket nut and bolt to 25 Nm (18 lb-ft).
- Install the drive belt.
- Install the spacer, flexplate and the bolts.
- Tighten the bolts in a criss-cross pattern to 80 Nm (59 lb-ft).
- Remove the engine from the stand.
CAUTION:
The crankshaft main bearings are precision fit. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION
for checking clearances.
NOTE:
Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
NOTE:
Lubricate the inner and outer sealing surfaces of the crankshaft rear seal with clean engine oil.
NOTE:
Lubricate the camshaft and the camshaft bearings with clean engine oil.
NOTE:
Lubricate the piston and connecting rod assemblies with clean engine oil.
NOTE:
Lubricate the connecting rod bearings with clean engine oil.
NOTE:
Lubricate the valve tappets with clean engine oil.
NOTE:
The "V" notch in the cylinder head gasket faces the front of the engine.
CAUTION:
All timing marks must be aligned with the No. 1 cylinder set on top dead center (TDC) of the compression stroke or the synchronizer assembly will not be installed correctly.
NOTE:
The crankshaft must not be turned until the camshaft synchronizer is installed.
NOTE:
If the oil pan is not secured within 4 minutes, 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.
NOTE:
Make sure the fasteners are clean and dry prior to installation.
CAUTION:
After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center of the compression stroke on the No. 1 cylinder.
CAUTION:
A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.
NOTE:
Always coat the synchronizer drive gear with clean engine oil prior to installation.
NOTE:
During installation, the arrow on the synchronizer alignment gauge will rotate clockwise as the gears engage.
NOTE:
If the lower intake manifold is not secured within 4 minutes, 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.
CAUTION:
If reusing the push rods and rocker arms, they must be installed in their original positions.
NOTE:
If the valve covers are not secured within 4 minutes, 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.
NOTE:
If the oil level indicator tube is not secured within 4 minutes, 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.
NOTE:
Clean all of the sealing surfaces. Inspect the upper intake manifold gaskets and install new gaskets as necessary.
NOTE:
Coat the sealing surfaces of the crankshaft damper with clean engine oil and coat the crankshaft damper keyway with silicone gasket and sealant.