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Section 1037 (Engine): Assembly: Engine: Assembly

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    All engines 

  1. Record the main bearing code found on the front of the engine block.
    Fig 1: Locating Main Bearing Code Label
    G04583819Courtesy of FORD MOTOR CO.
  2. Record the main bearing code found on the back of the crankshaft.
    Fig 2: Locating Main Bearing Code
    G03886015Courtesy of FORD MOTOR CO.
  3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart determine the required bearing grade for each main bearing.
    • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
    • Read down the column below the engine main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing.
    • As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is "2."
    • Repeat this process for the remaining four main bearings.
    Fig 3: Bearing Select Fit Chart (Standard Bearings)
    G03886016Courtesy of FORD MOTOR CO.
  4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing.
    Fig 4: Bearing Select Fit Chart
    G04583822Courtesy of FORD MOTOR CO.
    5. CAUTION: 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.
  5. Lubricate with clean engine oil and install the crankshaft upper main bearings into the cylinder block.
  6. Install the crankshaft onto the upper crankshaft thrust bearing and main bearings.
    Fig 5: Installing Crankshaft Onto Upper Crankshaft Main Bearings
    G03886018Courtesy of FORD MOTOR CO.
    7. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
    NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).
    Fig 6: Installing Rear Main Bearing Cap
    G03885912Courtesy of FORD MOTOR CO.
  7. Install the rear main bearing cap.
  8. Install the crankshaft lower main bearings, thrust bearing and thrust washer into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or dead-blow hammer.
    Fig 7: Tapping Main Bearing Cap On Cylinder Block
    G03905875Courtesy of FORD MOTOR CO.
    9. NOTE: The jack screws are a part of the main bearing cap assembly, and are screwed into the main caps, not the cylinder block.
    Fig 8: Identifying Tightening Sequence Of Jack Screws
    G03881922Courtesy of FORD MOTOR CO.
  9. Back out the jack screws against the cylinder block in two stages, in the sequence shown.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
  10. Install the bolts and tighten in two stages, in the sequence shown.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 21 Nm (15 lb-ft).
    Fig 9: Identifying Tightening Sequence Of Bolts
    G04002315Courtesy of FORD MOTOR CO.
  11. Tighten the bolts in two stages, in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 10: Identifying Tightening Sequence Of Main Bearing Cap Bolts
    G03885913Courtesy of FORD MOTOR CO.
  12. Check piston-to-cylinder block and ring clearances. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    13. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    NOTE: Make sure the piston arrow is facing forward.
    NOTE: The next three steps are for all eight connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.
    Fig 11: Installing Piston And Connecting Rod Assemblies
    G03885916Courtesy of FORD MOTOR CO.
  13. Use the special tools to install the piston and connecting rod assemblies.
    • Lubricate the piston and ring with clean engine oil.
    • Lubricate the rod bearings with clean engine oil.
    • Rotate the crankshaft as necessary.
    14. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 12: Removing Special Tools
    G04002318Courtesy of FORD MOTOR CO.
  14. Once the connecting rod is seated on the crankshaft journal, remove the special tools.
    15. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.
    NOTE: The connecting rod caps are of the cracked design and must make mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
    Fig 13: Positioning Lower Bearing And Connecting Rod Cap
    G04002319Courtesy of FORD MOTOR CO.
  15. Position the lower bearing and connecting rod cap, and install the new bolts loosely.
  16. Tighten the bolts in two stages, in the sequence shown.
    • Stage 1: Tighten to 43 Nm (32 lb-ft).
    • Stage 2: Rotate an additional 90-120 degrees.
    Fig 14: Identifying Tightening Sequence Of Connecting Rod Cap Bolts
    G03885918Courtesy of FORD MOTOR CO.
  17. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
    Fig 15: Tightening Sequence & Torque Specification Of Oil Pump Bolts
    G04002321Courtesy of FORD MOTOR CO.

    18. Both cylinder heads 

    CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS .
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seat correctly. Do not scratch the gasket.
    NOTE: RH head gasket shown; LH head gasket similar.
    Fig 16: Installing Head Gasket Over Dowel Pins
    G03881930Courtesy of FORD MOTOR CO.
  18. Install the head gasket over the dowel pins.
    19. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.
    CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS .
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: Do not allow the dowels to scratch the sealing of the cylinder head during cylinder head installation.
    NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.
    NOTE: RH cylinder head shown; LH cylinder head similar.
    Fig 17: Installing Cylinder Head On Dowels
    G03886030Courtesy of FORD MOTOR CO.
  19. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
  20. Tighten the cylinder head bolts in six stages, in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
    • Stage 3: Loosen the bolts a minimum of one full turn (360 degrees).
    • Stage 4: Tighten to 40 Nm (30 lb-ft).
    • Stage 5: Tighten an additional 90 degrees (1/4 turn).
    • Stage 6: Tighten an additional 90 degrees (1/4 turn).
    Fig 18: Identifying Tightening Sequence Of Cylinder Head Bolts
    G04002324Courtesy of FORD MOTOR CO.
  21. Remove the special tools from both ends of the cylinder head.
    Fig 19: Installing/Removing Special Tools On Both Ends Of Cylinder Head
    G03885649Courtesy of FORD MOTOR CO.
    22. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
    Fig 20: Identifying Hydraulic Lash Adjusters
    G04583838Courtesy of FORD MOTOR CO.
  22. Install the hydraulic lash adjusters in their original locations.
    23. NOTE: Lubricate the O-ring seal with clean engine oil.
    Fig 21: Installing Oil Lever Indicator Tube
    G04002032Courtesy of FORD MOTOR CO.
  23. Install the oil lever indicator tube.
    • Install a new O-ring seal on the oil level indicator tube.
  24. Install the LH exhaust manifold.
    • Install a new LH exhaust manifold gasket.
    • Install the LH exhaust manifold.
    • Tighten the nuts in the sequence shown.
    Fig 22: Tightening Sequence & Torque Specification Of LH Exhaust Manifold Bolts
    G04002328Courtesy of FORD MOTOR CO.
  25. Install the RH exhaust manifold.
    • Install a new RH exhaust manifold gasket.
    • Install the RH exhaust manifold.
    • Tighten the nuts in the sequence shown.
    Fig 23: Tightening Sequence & Torque Specification Of RH Exhaust Manifold Bolts
    G04002020Courtesy of FORD MOTOR CO.

    26. Engines with ratcheting timing chain tensioners 

    CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    NOTE: LH shown; RH similar.
    Fig 24: Compressing Tensioner Plunger Using Vise
    G04001957Courtesy of FORD MOTOR CO.
  26. Compress each tensioner plunger, using an edge or a vise.
  27. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
    Fig 25: Pushing Back And Holding Ratchet Mechanism
    G04001958Courtesy of FORD MOTOR CO.
  28. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 26: Pushing Ratchet Arm Back Into Tensioner Housing
    G04001959Courtesy of FORD MOTOR CO.
  29. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
    • Remove the tensioner from the vise.
    Fig 27: Installing Paper Clip Into Hole Of Tensioner Housing
    G03881578Courtesy of FORD MOTOR CO.

    30. Engines with non-ratcheting timing chain tensioners 

    CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body or permanent compression of the seal bead, will require replacement of the tensioner.
  30. Inspect the RH and LH timing chain tensioners.
    • Install new tensioners as necessary.
    31. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    NOTE: LH shown; RH similar.
    Fig 28: Compressing Tensioner Plunger Using Edge Of Vise
    G03885344Courtesy of FORD MOTOR CO.
  31. Compress each tensioner plunger, using a vise.
  32. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 29: Installing Retaining Clip On Tensioner
    G03881580Courtesy of FORD MOTOR CO.

    33. All engines 

  33. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
    Fig 30: Identifying Timing Chain Copper Links
    G03881581Courtesy of FORD MOTOR CO.
  34. Using the special tool, position the crankshaft.
    • Remove the special tool after crankshaft positioning.
    Fig 31: Positioning Crankshaft
    G03885349Courtesy of FORD MOTOR CO.
  35. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 32: Identifying Crankshaft Sprocket Flange
    G03881584Courtesy of FORD MOTOR CO.
  36. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts.
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts.
    Fig 33: Installing Timing Chain Guides - With Torque Specifications
    G03885348Courtesy of FORD MOTOR CO.
  37. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
    Fig 34: Identifying Timing Marks
    G04583473Courtesy of FORD MOTOR CO.
  38. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 35: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03962459Courtesy of FORD MOTOR CO.
  39. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 36: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03962460Courtesy of FORD MOTOR CO.
    40. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 37: Installing LH Timing Chain Tensioner - With Torque Specification
    G03885938Courtesy of FORD MOTOR CO.
  40. Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner.

    41. Engines with ratcheting timing chain tensioners 

  41. Remove the retaining clip from the LH timing chain tensioner.
    Fig 38: Removing Paper Clip From Hole Of Tensioner Housing
    G03881590Courtesy of FORD MOTOR CO.

    42. Engines with non-ratcheting timing chain tensioners 

  42. Remove the retaining clip from the LH timing chain tensioner.
    Fig 39: Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.

    43. All engines 

  43. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 40: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03948189Courtesy of FORD MOTOR CO.
  44. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 41: Aligning Copper (Marked) Link With Timing Marks On Camshaft Sprocket
    G03885941Courtesy of FORD MOTOR CO.
  45. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 42: Installing RH Timing Chain Tensioner - With Torque Specification
    G03886280Courtesy of FORD MOTOR CO.

    46. Engines with ratcheting timing chain tensioners 

  46. Remove the retaining clip from the RH timing chain tensioner.
    Fig 43: Removing Paper Clip From Hole Of RH Tensioner Housing
    G03881590Courtesy of FORD MOTOR CO.

    47. Engines with non-ratcheting timing chain tensioners 

  47. Remove the retaining clip from the RH timing chain tensioner.
    Fig 44: Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.

    48. All engines 

  48. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    Fig 45: Identifying Camshaft & Crankshaft Alignment Links/Marks
    G03962922Courtesy of FORD MOTOR CO.
  49. Rotate and camshaft until the lobe is in the up position.
    Fig 46: Positioning Lobe Of Camshaft Up
    G03881960Courtesy of FORD MOTOR CO.
  50. Install the special tool between the valve spring coil to prevent valve stem seal damage.
    Fig 47: Installing Special Tool Between Valve Spring Coils
    G03881599Courtesy of FORD MOTOR CO.
    51. NOTE: Lubricate the camshaft roller followers using clean engine oil.
    NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
    Fig 48: Installing Camshaft Roller Followers
    G03905495Courtesy of FORD MOTOR CO.
  51. Install the camshaft roller followers.
    1. Install the special tool.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original locations.
  52. Remove the special tool.
    Fig 49: Removing Special Tool
    G04002355Courtesy of FORD MOTOR CO.
  53. Install all eight spark plugs.
    Fig 50: Installing Spark Plugs
    G04002356Courtesy of FORD MOTOR CO.
  54. Install the crankshaft sensor ring.
    Fig 51: Installing Crankshaft Sensor Ring
    G04583449Courtesy of FORD MOTOR CO.
    55. NOTE: RH timing chain removed for clarity.
    NOTE: If the engine front cover is not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 52: Applying Bead Of Sealant Along Head-To-Block Surface And Oil Pan-To-Block Surface
    G03921154Courtesy of FORD MOTOR CO.
  55. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
  56. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 53: Installing Engine Front Cover
    G03881967Courtesy of FORD MOTOR CO.
  57. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
    Fig 54: Tightening Sequence & Torque Specification Of Engine Front Cover Bolts
    G04002360Courtesy of FORD MOTOR CO.
    58. NOTE: RH shown; LH similar.
    Fig 55: Installing Engine Mount
    G04002361Courtesy of FORD MOTOR CO.
  58. Install the RH and LH engine mounts.
  59. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
    Fig 56: Installing Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  60. Using the special tools, install the front oil seal.
    Fig 57: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool
    G03885953Courtesy of FORD MOTOR CO.
    61. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 58: Applying Sealant To Woodruff Key Slot On Crankshaft Pulley
    G04001916Courtesy of FORD MOTOR CO.
  61. Apply sealant to the Woodruff key slot on the crankshaft pulley.
  62. Using the special tool, install the crankshaft pulley.
    Fig 59: Installing Crankshaft Pulley Using Special Tool
    G03886064Courtesy of FORD MOTOR CO.
    63. NOTE: Use special tool 303-009 or suitable strap wrench to hold the pulley.
    Fig 60: Tightening Crankshaft Pulley Bolt
    G04002366Courtesy of FORD MOTOR CO.
  63. Tighten the crankshaft pulley bolt in four stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Rotate an additional 90 degrees (1/4 turn).
    64. NOTE: If the rear crankshaft seal retaining plate is not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    NOTE: The silicone must be applied on the groove along the retainer plate.
    Fig 61: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
    G03881975Courtesy of FORD MOTOR CO.
  64. Apply 4-mm (0.16-in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
  65. Install the rear oil seal retainer and loosely install the six bolts.
    Fig 62: Identifying Crankshaft Rear Oil Seal Retainer
    G04583880Courtesy of FORD MOTOR CO.
  66. Tighten the bolts in the sequence shown.
    Fig 63: Tightening Sequence Of Rear Oil Seal Retainer Bolts - With Torque Specification
    G03885983Courtesy of FORD MOTOR CO.
    67. CAUTION: Make sure the O-ring seal is in place and not damaged. A missing or damaged O-ring seal can cause foam in the lubrication system, low oil pressure and severe engine damage.
    NOTE: Clean and inspect the mating surfaces and install a new O-ring seal. Lubricate the O-ring seal with clean engine oil.
    Fig 64: Installing Oil Pump Screen Cover And Tube Spacer
    G04002370Courtesy of FORD MOTOR CO.
  67. Install the oil pump screen cover and tube spacer.
  68. Position the oil pump screen cover and tube, and install the bolts.
    Fig 65: Installing Oil Pump Screen Cover And Tube
    G04002371Courtesy of FORD MOTOR CO.
    69. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 66: Identifying Area For Applying Bead Of Silicone Gasket And Sealant
    G04583522Courtesy of FORD MOTOR CO.
  69. Apply the sealant at the rear oil seal retainer to cylinder block sealing surface.
  70. Apply sealant at the front cover-to-cylinder block sealing surface.
    Fig 67: Applying Sealant At Front Cover-To-Cylinder Block Sealing Surface
    G04002373Courtesy of FORD MOTOR CO.
  71. Position the oil pan gasket, the oil pan and the bolts on the engine.
    Fig 68: Installing Oil Pan
    G04002240Courtesy of FORD MOTOR CO.
  72. Tighten the bolts in two stages, in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Rotate an additional 60 degrees.
    Fig 69: Identifying Tightening Sequence Of Oil Pan Bolts
    G03886098Courtesy of FORD MOTOR CO.
  73. Install the oil filter adapter.
    • Tighten the bolts in the torque sequence shown.
    Fig 70: Tightening Sequence & Torque Specification Of Oil Filter Adapter Bolts
    G04002376Courtesy of FORD MOTOR CO.
    74. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
    Fig 71: Installing Coolant Pump
    G04002377Courtesy of FORD MOTOR CO.
  74. Install the coolant pump.
    1. Lubricate the new O-ring seal using engine coolant.
    2. Position the coolant pump into the engine block.
    3. Install the bolts.
  75. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 72: Coolant Pump Pulley Bolts Torque Specification
    G04002475Courtesy of FORD MOTOR CO.
  76. Position the belt idler pulley and install the bolt.
    Fig 73: Accessory Drive Belt Idler Pulley Bolt Torque Specification
    G04001929Courtesy of FORD MOTOR CO.
    77. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 74: Applying Sealant In Two Places Where Engine Front Cover Meets Cylinder Head
    G04001910Courtesy of FORD MOTOR CO.
  77. Apply sealant in two places where the engine front cover meets the cylinder head.
  78. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
    Fig 75: Tightening Sequence & Torque Specification Of Valve Cover Bolts
    G04001911Courtesy of FORD MOTOR CO.
    79. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 76: Applying Sealant In Two Places Where Engine Front Cover Meet Cylinder Head
    G04001904Courtesy of FORD MOTOR CO.
  79. Apply sealant in two places where the engine front cover meet the cylinder head.
  80. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
    Fig 77: Tightening Sequence & Torque Specification Of Valve Cover Bolts
    G04001905Courtesy of FORD MOTOR CO.
  81. Install the knock sensor (KS) and the bolts.
    Fig 78: Installing Knock Sensor
    G04002384Courtesy of FORD MOTOR CO.
  82. Inspect the O-rings seals. Install new seals if necessary.
    Fig 79: Installing O-Rings Seals
    G03948106Courtesy of FORD MOTOR CO.
  83. Install the coolant bypass tube.
    Fig 80: Installing Coolant Bypass Tube
    G04002386Courtesy of FORD MOTOR CO.
  84. Install the ground strap on the rear of the RH cylinder head.
    1. Install the stud bolt.
    2. Install the ground strap.
    3. Install the retaining nut.
    Fig 81: Installing Ground Strap On Rear Of RH Cylinder Head
    G04002387Courtesy of FORD MOTOR CO.
    85. NOTE: Align the gasket locator tabs to slots in cylinder head.
    Fig 82: Installing Intake Manifold Gaskets
    G04002107Courtesy of FORD MOTOR CO.
  85. Install new intake manifold gaskets.
  86. Install the intake manifold and hand-tighten the bolts at the locations shown.
    Fig 83: Installing Intake Manifold Bolts
    G04002389Courtesy of FORD MOTOR CO.
  87. Install the eight ignition coils and tighten the eight bolts.
    Fig 84: Ignition Coil Bolts Torque Specification
    G04001862Courtesy of FORD MOTOR CO.
  88. Install the crash bracket and loosely install the bolt and the stud.
    Fig 85: Installing Bolt & Stud
    G03881486Courtesy of FORD MOTOR CO.
  89. Install the thermostat.
    Fig 86: Installing Thermostat
    G04002392Courtesy of FORD MOTOR CO.
  90. Install the coolant outlet adapter and loosely install the bolts.
    Fig 87: Installing Coolant Outlet Adapter Bolts
    G04002104Courtesy of FORD MOTOR CO.
  91. Tighten the bolts in the sequence shown.
    Fig 88: Tightening Sequence & Torque Specification Of Intake Manifold Bolts
    G04002394Courtesy of FORD MOTOR CO.
  92. Tighten the stud.
    Fig 89: Stud Torque Specification
    G04001865Courtesy of FORD MOTOR CO.
  93. Tighten the bolts.
    Fig 90: Tightening Bolts To Torque Specification
    G04002396Courtesy of FORD MOTOR CO.
  94. Install the throttle body and the bolts.
    • Tighten to 10 Nm (89 lb in).
    Fig 91: Throttle Body Bolts Torque Specification
    G03882005Courtesy of FORD MOTOR CO.
  95. Connect the throttle control and throttle positioning sensor electrical connector.
    Fig 92: Locating Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  96. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
    Fig 93: Connecting Exhaust Gas Recirculation Tube To EGR Valve
    G04002399Courtesy of FORD MOTOR CO.
  97. Connect the EGR tube to the exhaust manifold connector.
    Fig 94: Connecting EGR Tube To Exhaust Manifold Connector
    G04002400Courtesy of FORD MOTOR CO.
  98. Position the fuel charging wiring at two locations at the back of the intake manifold.
  99. Install the generator.
    Fig 95: Generator Bolts Torque Specification
    G04002401Courtesy of FORD MOTOR CO.
  100. Install the generator mounting bracket.
    Fig 96: Generator Mounting Bracket Bolts Torque Specification
    G04002498Courtesy of FORD MOTOR CO.
  101. Connect the generator electrical connector.
    Fig 97: Connecting Generator Electrical Connector
    G04001875Courtesy of FORD MOTOR CO.
  102. Position the vacuum harness and connect the vacuum hoses for the evaporative emission (EVAP) canister purge valve, the main chassis hose and the EGR valve.
    Fig 98: Connecting Evaporative Emission Canister Purge Valve Vacuum Hoses, Main Chassis Hose And EGR Valve
    G04001837Courtesy of FORD MOTOR CO.
  103. Install the generator wiring harness anchor to the LH front stud.
    Fig 99: Installing Generator Wiring Harness Anchor To LH Front Stud
    G04002208Courtesy of FORD MOTOR CO.
  104. Connect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 100: Connecting Engine Coolant Temperature Sensor Electrical Connector
    G04001853Courtesy of FORD MOTOR CO.
  105. Connect the crankcase ventilation tube.
    Fig 101: Connecting Crankcase Ventilation Tube
    G04002407Courtesy of FORD MOTOR CO.
  106. Install the EGR tube heat shield.
    Fig 102: Installing EGR Tube Heat Shield
    G03881459Courtesy of FORD MOTOR CO.
  107. Connect the eight fuel injector electrical connectors.
    Fig 103: Connecting Fuel Injector Electrical Connectors
    G04001835Courtesy of FORD MOTOR CO.
  108. Connect the eight ignition coil electrical connectors.
    Fig 104: Connecting Ignition Coil Electrical Connectors
    G03881457Courtesy of FORD MOTOR CO.
  109. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 105: Connecting Camshaft Position Sensor Electrical Connector
    G04002211Courtesy of FORD MOTOR CO.
  110. Connect the radio interference capacitor electrical connector.
    Fig 106: Connecting Radio Interference Capacitor Electrical Connector
    G04002412Courtesy of FORD MOTOR CO.
  111. Connect the KS electrical connector and install the harness retainer to the intake manifold.
    Fig 107: Locating Knock Sensor (KS) Electrical Connector
    G03881828Courtesy of FORD MOTOR CO.
  112. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 108: Connecting Cylinder Head Temperature Sensor Electrical Connector
    G04002207Courtesy of FORD MOTOR CO.
  113. Connect the ground wire to the right rear fuel rail stud.
    Fig 109: Connecting Ground Wire To Right Rear Fuel Rail Stud
    G04002415Courtesy of FORD MOTOR CO.
  114. Install the battery cables and the bolt.
  115. NOTE: RH shown; LH similar. Install the RH and LH lighting brackets.
    Fig 110: Installing Lighting Brackets
    G04002080Courtesy of FORD MOTOR CO.
  116. Remove the engine from the engine stand.
    Fig 111: Removing Engine From Engine Stand
    G03882120Courtesy of FORD MOTOR CO.
  117. Using the special tool, install the crankshaft rear oil seal.
    Fig 112: Installing Crankshaft Rear Oil Seal
    G04002418Courtesy of FORD MOTOR CO.
  118. Using the special tools, install the crankshaft oil slinger.
    Fig 113: Installing Crankshaft Oil Slinger
    G04002419Courtesy of FORD MOTOR CO.
  119. Install the engine/transmission spacer plate.
    Fig 114: Installing Engine/Transmission Spacer Plate
    G03882121Courtesy of FORD MOTOR CO.
  120. Position the flexplate and install the bolts in the sequence shown.
Fig 115: Tightening Sequence & Torque Specification Of Flexplate Bolts
G04002514Courtesy of FORD MOTOR CO.
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