Part 3

Engine


















Engine Upper










Engine Upper - LH Cylinder Head










Engine Upper - RH Cylinder Head










Engine Front










Lower Engine Block (View 1)










Lower Engine Block (View 2)









NOTICE: 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, may 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.

NOTE: Early build engine crankshaft main bearing cap bolt torque is different than late build engines. Although these parts are serviced in the same way, the torque has changed between early build and late build engines. The level of the engine can be determined by inspecting the engine code label. Early build engines are built with the engine code of (1G 372 BA) and late build engines are built with engine code (1G 372 CA).

101. As a post-check, verify correct alignment of all timing marks.
- There is 48 links in between the RH intake VCT (Variable Camshaft Timing) assembly colored link (1) and the LH intake VCT (Variable Camshaft Timing) assembly colored link (2).

- There is 35 links in between RH intake VCT (Variable Camshaft Timing) assembly colored link (2) and the 2 crankshaft sprocket links (3).






102. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

NOTE: A slight twisting motion will aid in the installation of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.

Install the LH intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.






103. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

NOTE: A slight twisting motion will aid in the installation of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.

Install the RH intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.






104. Remove the RH Camshaft Holding Tool.





105. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 45 degrees.






106. Remove the LH Camshaft Holding Tool.





107. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 45 degrees.






108. NOTE: Use Spindle Bearing Installer 205-149 to install the seal.

If removed, using the Spindle Bearing Installer, install the front cover radial seal from the rear side of the front cover.






109. NOTICE: Failure to use Motorcraft(R) High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTICE: Do not expose the Motorcraft(R) High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow these instructions may cause engine oil leakage.

NOTE: The engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 must be installed within 10 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 in) bead of Motorcraft(R) High Performance Engine RTV Silicone on the inside edge of the engine front cover to the engine front cover sealing surfaces including the 2 engine front cover bolt bosses.
- Apply a 5.5 mm (0.21 in) bead of Motorcraft(R) 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.






110. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 and tighten sequence shown in 3 stages:

- Stage 1: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 in sequence to 10 Nm (89 lb-in).

- Stage 2: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19 and 20 in sequence to 20 Nm (177 lb-in) then an additional 45 degrees.

- Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees.






111. Install the remaining 12 engine front cover bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 16 and 22. Tighten all of the engine front cover bolts in the sequence shown in 3 stages:
- Stage 1: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14 and 16 to 10 Nm (89 lb-in).

- Stage 2: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14 and 16 to 20 Nm (177 lb-in) then an additional 45 degrees.

- Stage 3: Tighten bolt 22 to 10 Nm (89 lb-in) then an additional 45 degrees.






112. Using a new gasket, install the oil filter adapter and the 5 bolts and tighten in sequence shown.
- Tighten to 10 Nm (89 lb-in) and then an additional 45 degrees.






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

If equipped, install the new oil cooler and the mounting bolt.
- Tighten to 58 Nm (43 lb-ft).






114. Install the Crankshaft Position (CKP) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).






115. Install the 2 RH Camshaft Position (CMP) sensors and the bolts.
- Tighten to 10 Nm (89 lb-in).






116. Install the 2 LH CMP (Camshaft Position) sensors and the bolts.
- Tighten to 10 Nm (89 lb-in).






117. Install 6 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).






118. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 19 Nm (168 lb-in).

- Stage 2: Tighten to 25 Nm (18 lb-ft).






119. Install the RH exhaust manifold heat shield and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






120. NOTE: Installation of new seals is only required if damaged seals were removed.

Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.






121. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT (Variable Camshaft Timing) solenoid seal(s).






122. NOTICE: Failure to use the correct Motorcraft(R) 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 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.






123. Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).






124. Ensure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the VCT (Variable Camshaft Timing) oil control solenoid electrical connector or the VCT (Variable Camshaft Timing) seal may leak oil.





125. NOTICE: Only use hand tools when installing the spark plugs, or damage may occur to the cylinder head or spark plug.

Install the 3 RH spark plugs.
- Tighten to 15 Nm (133 lb-in).


126. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
- To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.






127. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).






128. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).






129. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 19 Nm (168 lb-in).

- Stage 2: Tighten to 25 Nm (18 lb-ft).






130. Install the LH exhaust manifold heat shield and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






131. NOTE: Installation of new seals is only required if damaged seals were removed.

Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.






132. NOTE: Installation of new seals is only required if damaged seals were removed.

Using the Differential Bearing Cone Installer and Handle, install new VCT (Variable Camshaft Timing) solenoid seal(s).






133. NOTICE: Failure to use the correct Motorcraft(R) 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 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.






134. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).






135. Ensure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the VCT (Variable Camshaft Timing) oil control solenoid electrical connector or the VCT (Variable Camshaft Timing) seal may leak oil.





136. NOTICE: Only use hand tools when installing the spark plugs, or damage may occur to the cylinder head or spark plug.

Install the 3 LH spark plugs.
- Tighten to 15 Nm (133 lb-in).


137. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
- To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.






138. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).






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

Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7 bolts and tighten in the sequence shown in 2 stages:

- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.






140. Install the coolant pump pulley and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).






141. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.

Install the thermostat housing and the 4 bolts and tighten in the sequence shown in 2 stages:

- Stage 1: Tighten to 8 Nm (71 lb-in).

- Stage 2: Tighten an additional 45 degrees.






142. Install the heater hose bracket on the valve cover stud bolt and install the nut.
- Tighten to 8 Nm (71 lb-in).






143. Install the RH cylinder block drain plug.
- Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.






144. Install the LH cylinder block drain plug.
- Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.






145. Install the accessory drive belt tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).






146. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.






147. Lubricate the crankshaft front seal inner lip with clean engine oil.

148. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.






149. Using the Strap Wrench, 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.






150. Attach all of the wiring harness retainers to the LH cylinder head, valve cover and stud bolts.