Assembly - Engine

Special Service Tools / General Equipment

	100-002 (TOOL-4201-C) Dial Indicator Holding Fixture
	205-153 (T80T-4000-W) Handle
	303-096 (T74P-6150-A) Installer, Front Camshaft Seal TKIT-2009TS-F
	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
	303-1416 Tool, Crankshaft Damper Holder TKIT-2008ET-FLM
	303-1699 Tool, Crank Sensor Alignment
	303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-FLM TKIT-1988-F TKIT-1988-LM
	303-465 Camshaft Timing Tool TKIT-1994-LMH/MH2 TKIT-1994-FX/FMX/FLMX
	303-507 Timing Pin, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-RYAD
Mounting Stand
Hose Clamp Removal/Installation Tool
Steel rule with rounded end
Piston Ring Compressor

Materials

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as specified in this procedure. The crankshaft pulley and crankshaft sprocket are not keyed to the crankshaft. The crankshaft, crankshaft sprocket and pulley are joined to each other by friction. For this reason, the crankshaft sprocket will also come loose 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 with special service tools, otherwise serious engine damage may occur.

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 oil pan may cause engine failure.

1. 1
   Install the oil squirters.
   Torque: 35 lb-in (4 N·m)

   

2. 2
   Measure each crankshaft main journal diameter in at least 2 directions and record the smallest diameter for each journal.

   

3. 3
   Position the main bearing beam in the cylinder block so that the main bearing beam is flush with the rear face of the cylinder block, and hand-tighten the original main bearing beam bolts.

   

4. 4
   Tighten the bolts in the sequence shown in 3 stages.
   Torque:
   Stage 1: 44 lb-in (5 N·m)
   Stage 2: 18 lb-ft (25 N·m)
   Stage 3: 90°

   

5. 5
   Measure the bore diameter of each crankshaft main bearing bore in the cylinder block.

   

6. 6
   Using the chart, select the correct class of main bearings.
   

   1. Crankshaft Journal Diameter

   2. Cylinder Block Bore Diameter

   3. Blue upper bearing: 1 / Blue lower bearing: 1

   4. Blue upper bearing: 2 / Brown lower bearing: 1

   5. Brown upper bearing: 2 / Brown lower bearing: 2

   6. Black upper bearing: 3 / Brown lower bearing: 2

   7. Black upper bearing: 3 / Black lower bearing: 3

   

7. 7
   Using the original connecting rod cap bolts, install the connecting rod caps and bolts. Tighten in 3 stages.
   Torque:
   Stage 1: 89 lb-in (10 N·m)
   Stage 2: 21 lb-ft (29 N·m)
   Stage 3: 90°

   

8. 8
   Measure the connecting rod big end bore in 2 directions. Record the smallest value for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts.

   

9. 9
   Measure each crankshaft connecting rod journal diameter in at least 2 directions. Record the smallest measurement for each connecting rod journal.

   

10. 10
    Using the chart, select the correct class of connecting rod bearings.
    

    1. Crankshaft Journal Diameter

    2. Connecting Rod Journal Diameter

    3. Green upper bearing: 1 / Green lower bearing: 1

    4. Upper bearing Blue: 2 / Lower bearing Green: 1

    5. Blue upper bearing: 2 / Blue lower bearing: 2

    6. Upper bearing Red: 3 / Lower bearing Blue: 2

    7. Upper bearing Red: 3 / Lower bearing Red: 3

    

11. 11
    • Remove the bolts in the sequence shown and the main bearing beam.

    • Discard the main bearing beam bolts.

    

12. 12
    Lubricate with clean engine oil and install the upper crankshaft main bearings.

    

13. 13
    Lubricate with clean engine oil and install the lower crankshaft main bearings.

    

14. 14
    Lubricate with clean engine oil and install the crankshaft.

    

15. 15
    Lubricate the main bearing beam with clean engine oil.

    

16. 16
    Install the main bearing beam flush.

    

17. 17
    Install new bolts and tighten in the sequence shown in 3 stages.
    Torque:
    Stage 1: 44 lb-in (5 N·m)
    Stage 2: 18 lb-ft (25 N·m)
    Stage 3: 90°

    

18. 18
    • Position the crankshaft toward the rear of the cylinder block.

    • Zero the dial indicator using the holder.
      Use Special Service Tool: 100-002 (TOOL-4201-C) Dial indicator holding fixture.

    • Move the crankshaft toward the front of the cylinder block. Mark and record the crankshaft end play.

    • Crankshaft end play specification is 0.22-0.45 mm (0.008-0.018 in). If the crankshaft end play exceeds the specified range, install new components as necessary.

    

19. 19
    Lubricate with clean engine oil and install the connecting rod bearings.

    

20. 20
    1. Upper oil control ring rail gap location.

    2. Oil control ring spacer gap location.

    3. Oil control ring lower rail end gap.

    

21. 21
    Using the piston ring compressor, install the pistons.
    Use General Equipment: Piston ring compressor.

    

22. 22
    Install the connecting rod caps and new bolts. Tighten in 3 stages.
    Torque:
    Stage 1: 89 lb-in (10 N·m)
    Stage 2: 21 lb-ft (29 N·m)
    Stage 3: 90°

    

23. 23

    NOTICE: Rotate the crankshaft clockwise only.

    • Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.

    • Slowly rotate the crankshaft clockwise until the crankshaft counterweight contacts the special tool. The engine is now at TDC.

    

24. 24
    Install the original shims in their original positions on the balance shaft module mounting surfaces. With the balance shaft marks at TDC, slowly install the balance shaft module onto the cylinder block to avoid interference between the crankshaft drive gear and the balance shaft driven gear.

    

25. 25
    Install the bolts and tighten in the sequence shown in 2 stages.
    Torque:
    Stage 1: 18 lb-ft (25 N·m)
    Stage 2: 38 lb-ft (52 N·m)

    

26. 26

    NOTICE: Rotate the crankshaft clockwise only.

    • Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

    • Rotate the crankshaft to make sure there is no binding between the balance shaft gear and the crankshaft gear.

    

27. 27

    NOTICE: Rotate the crankshaft clockwise only.

    1. Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.

    2. Slowly rotate the crankshaft clockwise until the crankshaft counterweight contacts the special tool.

    3. Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

    

28. 28
    • Position as shown. Measure the gear backlash.
      Use Special Service Tool: 100-002 (TOOL-4201-C) Dial Indicator Holding Fixture.

    • Position the dial indicator with holder (1) on the hex key at 80 mm (3.149 in) above the center of the driven gear shaft (2) on the balance shaft module.

    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.

    • Balance shaft backlash specification is 0.005 to 0.101 mm (0.00019 to 0.0039 in).

    • If the backlash exceeds the specified range, perform the balance shaft backlash check procedure.
      Refer to Balance Shaft Backlash (Engine 303-01C, General Procedures).

    

29. 29

    NOTICE: Rotate the crankshaft clockwise only.

    1. Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.

    2. Slowly rotate the crankshaft clockwise until the crankshaft counterweight contacts the special tool. The engine is now at TDC and must remain at TDC until the timing drive components and crankshaft pulley are installed.

    

30. 30
    Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and turn the oil pump by hand.
    Refer to: Specifications (Engine 303-01C, Specifications).
31. 31
    Install a new oil pump gasket.

    

32. 32
    Install the oil pump and the bolts. Tighten in the sequence shown in 2 steps.
    Material: Motorcraft® Metal Surface Prep Towelettes / ZC-31-B
    Torque:
    Step 1: 89 lb-in (10 N·m)
    Step 2: 177 lb-in (20 N·m)

    

33. 33
    Lubricate a new gasket with clean engine oil and install.

    

34. 34
    Install the oil pick-up tube and the bolts.
    Torque: 89 lb-in (10 N·m)

    

35. 35
    • Using the special service tool, install the rear crankshaft oil seal onto the crankshaft.
      Use special service tool: 303-328 (T88P-6701-B1) Replacer, rear oil seal.

    • Install the bolts and tighten in the sequence shown.
      Torque: 89 lb-in (10 N·m)

    

36. 36
    Apply a 3 mm (0.12 in) bead of silicone sealant.
    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    

37. 37
    Install the oil pan and hand-tighten the bolts.

    

38. 38
    Using a straightedge, align the front face of the oil pan flush with the front face of the cylinder block.
    Use common shop equipment: steel rule with rounded ends.

    

39. 39
    Tighten the bolts in the sequence shown.
    Torque:
    Fasteners 1-9:
    Stage 1: 177 lb-in (20 N·m)
    Stage 2: 45°
    Fasteners 10-11:
    Stage 3: 177 lb-in (20 N·m)
    Stage 4: 90°
    Fasteners 12-13:
    Stage 5: 177 lb-in (20 N·m)
    Stage 6: 45°

    

40. 40
    Remove excess sealant from the junction of the cylinder block and the oil pan.

    

41. 41
    Install the cylinder head locating dowels.

    

42. 42
    Apply a 6 mm (0.24 in) bead of silicone sealant.
    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    

43. 43
    Install a new cylinder head gasket.

    

44. 44
    Install the cylinder head and new bolts. Tighten in the sequence shown in 5 steps. Torque:
    Step 1: 62 lb-in (7 N·m)
    Step 2: 133 lb-in (15 N·m)
    Step 3: 33 lb-ft (45 N·m)
    Step 4: 90°
    Step 5: 90°

    

45. 45
    Remove the excess sealant at the junction of the cylinder block and the cylinder head.

    

46. 46
    Install a new plug gasket.

    

47. 47
    Install the plug and bolts.
    Torque: 177 lb-in (20 N·m)

    

48. 48
    If equipped.
    

    • Install the heater block.
      Torque: 41 lb-ft (55 N·m)

    

49. 49
    Install new studs.
    Torque: 150 lb-in (17 N·m)

    

50. 50
    Install the valve lifters.

    

51. 51
    Lubricate the camshafts with clean engine oil and install them into the cylinder head.

    

52. 52
    • Lubricate the camshaft bearing caps with clean engine oil and install the camshaft bearing caps and bolts.

    • Tighten the camshaft bearing cap bolts by hand, one turn at a time, until seated.

    • Tighten the bolts in the sequence shown in 2 steps.
      Torque:
      Step 1: 62 lb-in (7 N·m)
      Step 2: 142 lb-in (16 N·m)

    

53. 53
    Install the VCT oil control solenoid and bolt.
    Torque: 97 lb-in (11 N·m)

    

54. 54
    Install the oil pump drive sprocket, chain and bolt.
    Torque: 18 lb-ft (25 N·m)

    

55. 55
    1. Install the timing chain tensioner and shouldered bolts.
       Torque: 89 lb-in (10 N·m)

    2. Press the tensioner spring down and position the spring under the shouldered bolt.

    

56. 56
    Install the Special Service Tool: 303-465 Camshaft Timing Tool.

    

57. 57
    Install the camshaft sprocket and bolts.

    

58. 58
    Install the timing chain guide and the bolts.
    Torque: 89 lb-in (10 N·m)

    

59. 59
    Install the timing chain.

    

60. 60
    Install the timing chain tensioner arm.

    

1. 1
   Reset the timing chain tensioner.
   

   1. Install the timing chain tensioner in a vise with soft jaws.

   2. Spread the ends of the ratchet clip apart.

   3. Using a vise with soft jaws, compress the piston to its original position.

   4. Install the locking pin into the 2 holes of the timing chain tensioner housing to hold the plunger in place.

   

2. 2
   1. Install the timing chain tensioner and the bolts.
      Torque: 89 lb-in (10 N·m)

   2. Remove the locking pin.

   

3. 3
   Tighten the camshaft sprocket bolts in 2 steps.
   Torque:
   Step 1: 30 lb-ft (40 N·m)
   Step 2: 60°

   

4. 4
   Apply a 15 mm (0.59 in) diameter drop of silicone sealant to the junction of the cylinder head and cylinder block and the junction of the cylinder block and oil pan area.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

   

5. 5
   Apply a 3 mm (0.12 in) bead of silicone sealant to the outer sealing surfaces of the front cover. Apply a 2 mm (0.08 in) bead of silicone sealant to the inner sealing surfaces.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

   

6. 6
   Install the front cover and bolts. Tighten in the sequence shown.
   Torque:
   Step 1: Bolts 1-3: 35 lb-ft (48 N·m)
   Step 2: Bolts 4-16: 89 lb-in (10 N·m)
   Step 3: Bolt 17: 35 lb-ft (48 N·m)
   Step 4: Bolts 18-22: 89 lb-in (10 N·m)

   

7. 7
   Using the special tool, lubricate and install the front crankshaft oil seal.
   Use special service tool: 303-096 (T74P-6150-A) Installer, front camshaft oil seal.

   

8. 8
   Install the crankshaft pulley onto the crankshaft so that the pulley keyway is at the 6 o'clock position.

   

9. 9
   Install a standard M6 x 18 mm bolt through the crankshaft pulley and thread it into the front cover.

   

10. 10
    Using the special tool, tighten the new crankshaft pulley bolt in 2 steps.
    Use special service tool: 303-1416 Holding tool, crankshaft damper.
    Torque:
    Step 1: 74 lb-ft (100 N·m)
    Step 2: 90°

    

11. 11
    Remove the standard M6 x 18 mm bolt.

    

12. 12
    Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

    

13. 13
    Remove the special service tool: 303-465 Camshaft Timing Tool.

    

14. 14
    Rotate the crankshaft clockwise one and three-quarter turns.

    

15. 15

    NOTICE: Rotate the crankshaft clockwise only.

    • Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.

    • Rotate the crankshaft clockwise until the crankshaft contacts the special tool.

    

16. 16
    Install the standard M6 x 18 mm bolt. Check the position of the crankshaft pulley. If the bolt cannot be installed, the engine valve timing must be adjusted.

    

17. 17
    If the camshaft locating plate cannot be installed, the engine valve timing must be adjusted.
    Install special service tool: 303-465 Camshaft timing tool.

    

18. 18
    Remove the special service tool: 303-465 Camshaft Timing Tool.

    

19. 19
    Install the CKP sensor and bolts.

    

20. 20
    If the special service tool mark does not align with the TDC tooth marked on the crankshaft pulley, loosen the CKP sensor bolts and adjust the sensor until the tool can be installed, then tighten.
    Use the recommended tool: 303-1699 Crankshaft Sensor Alignment Tool. The shown tool or a commercially available equivalent may be used.
    Torque: 62 lb-in (7 N·m)

    

21. 21
    Remove the special tool: 303-1699 Crankshaft sensor alignment tool.

    

22. 22
    Remove the standard M6 x 18 mm bolt.

    

23. 23
    Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.

    

24. 24
    Install the engine plug bolt.
    Torque: 177 lb-in (20 N·m)

    

25. 25
    Install the crankshaft pulley cover.

    

26. 26
    Install the engine mount studs.
    Torque: 106 lb-in (12 N·m)

    

27. 27
    Inspect the O-ring of the engine coolant outlet assembly and replace if necessary.

    

28. 28
    Install the coolant outlet pipe and bolts.
    Torque: 89 lb-in (10 N·m)

    

29. 29
    Using the special service tools, install the VCT oil control solenoid seal.
    Special Service Tool: 303-1247 Spark Plug Tube Seal Remover and Installer for VCT, 205-153 (T80T-4000-W) Handle.

    

30. 30
    Inspect and, if necessary, install new valve cover gaskets.

    

31. 31
    Apply a 6 mm (0.24 in) bead of silicone sealant.
    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    

32. 32
    Install the valve cover and tighten the bolts in the sequence shown.
    Torque: 89 lb-in (10 N·m)

    

33. 33
    Inspect the ignition coil boots for cracks, tears or splits. Replace any damaged coil boot on the spark plug.

    

34. 34
    Install the ignition coil onto the spark plugs and bolts.
    Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESA-M1C200-A) (ESE-M1C171-A)
    Torque: 71 lb-in (8 N·m)

    

35. 35
    Install the oil level indicator.

    

36. 36
    Install the fuel injector retainers and fuel injector O-rings. Lubricate the fuel injector O-rings.

    

37. 37
    Install the fuel injectors into the fuel rail.

    

38. 38
    Install the fuel rail assembly and studs.
    Torque:
    Stage 1: 18 lb-ft (25 N·m)
    Stage 2: 30°

    

39. 39
    Install the radio capacitor and nut.

    

40. 40
    Install a new gasket.
    Material: Motorcraft® Metal Surface Preparation Wipes / ZC-31-B

    

41. 41
    Install the oil filter adapter and bolts.
    Torque: 18 lb-ft (25 N·m)

    

42. 42
    Install the oil pressure sensor.
    Torque: 97 lb-in (11 N·m)

    

43. 43
    If equipped.
    Align the oil cooler locating tab with the retainer on the oil filter adapter.

    

44. 44
    If equipped.
    Install the oil cooler.
    Torque: 41 lb-ft (55 N·m)

    

45. 45
    Install the converter cover.

    

46. 46
    Inspect the water inlet cover gasket and replace if necessary.

    

47. 47
    Install the water inlet cover and bolts.
    Torque: 89 lb-in (10 N·m)

    

48. 48
    Inspect the PCV oil separator gasket and replace if necessary.

    

49. 49
    Rotate the PCV tube before installation.

    

50. 50
    Install the PCV oil separator and tighten the bolts.
    Torque: 89 lb-in (10 N·m)

    

51. 51
    Rotate the PCV tube back to its original position.

    

52. 52
    Install the KS and bolt.
    Torque: 177 lb-in (20 N·m)

    

53. 53
    Inspect the intake manifold gaskets and replace if necessary.

    

54. 54
    Install the intake manifold and connect the PCV oil separator tube.

    

55. 55
    Install the intake manifold in position and install the bolts. Tighten the bolts in the sequence shown.
    Torque: 159 lb-in (18 N·m)

    

56. 56
    Install the water outlet housing, bolts and hoses. Tighten the bolts by hand.

    

57. 57
    Lubricate the O-ring with clean engine oil. Replace the O-ring if necessary.

    

58. 58
    Lubricate the O-ring with clean engine oil. Replace the O-ring if necessary.

    

59. 59
    Install the EGR cooler outlet temperature sensor.

    

60. 60
    Install the EGR outlet tube and fasteners.

    

61. 61
    • Install a new gasket.

    • Install the EGR valve and fasteners, then tighten them in the sequence shown.
      Torque: 89 lb-in (10 N·m)

    

62. 62
    Install the EGR back-pressure sensor.
    Torque: 97 lb-in (11 N·m)

    

63. 63
    Install the EGR outlet tube gasket.

    

64. 64
    Inspect the exhaust gas recirculation (EGR) cooler O-ring and replace if necessary.

    

65. 65
    Lubricate the new EGR cooler O-ring with a small amount of engine oil.

    

66. 66
    Install the EGR valve and EGR cooler assembly.

    

67. 67
    Install the EGR assembly bolt and at this stage tighten the bolt by hand only.

    

68. 68
    Install the EGR assembly bolt.
    Torque: 89 lb-in (10 N·m)

    

69. 69
    Install the EGR assembly bolts and at this stage tighten the bolts by hand only.

    

70. 70
    Tighten in the sequence shown.
    Torque:
    1: 89 lb-in (10 N·m)
    2: 89 lb-in (10 N·m)
    3: 89 lb-in (10 N·m)
    4: 89 lb-in (10 N·m)
    5: 18 lb-ft (25 N·m)

    

71. 71
    Tighten in the sequence shown.
    Torque:
    Stage 1: 89 lb-in (10 N·m)
    Stage 2: 45°

    

72. 72
    Install the EGR differential pressure feedback sensor assembly and fasteners.
    Torque: 89 lb-in (10 N·m)

    

73. 73
    Connect the differential pressure sensor hoses.

    

74. 74
    Install the fuel line bracket and nut.

    

75. 75
    Remove the bolts, pin retainers and fuel vapor tube.
    Refer to: Quick Release Coupling (310-00C Fuel System - General Information, General Procedures).
    Torque: 27 lb-in (3 N·m)

    

76. 76
    Install the crankcase vent tube, fuel line and pin retainer.
    Refer to: Quick Release Coupling (310-00C Fuel System - General Information, General Procedures).
    Refer to: Spring Lock Couplings (310-00C Fuel System - General Information, General Procedures).

    

77. 77
    Install the wiring harness, connect the electrical connectors and secure the retainers.

    

78. 78
    Connect the CHT sensor electrical connector and slide the boot into place.

    

79. 79
    Connect the electrical connectors.

    

80. 80
    Connect the CKP electrical connector and secure the pin-type retainers.

    

81. 81
    Install the thermostat housing in position, install the studs and coolant hose.
    Use common service equipment: hose clamp removal and installation tool.
    Torque: 35 lb-ft (47 N·m)

    

82. 82
    Install the bracket and fasteners.
    Torque: 18 lb-ft (25 N·m)

    

83. 83
    Install the coolant pump and fasteners.
    Torque: 18 lb-ft (25 N·m)

    

84. 84
    Install the A/C compressor bracket and bolts.
    Torque: 18 lb-ft (25 N·m)

    

85. 85
    Install the A/C compressor and fasteners.
    Torque: 18 lb-ft (25 N·m)

    

86. 86
    Install the coolant hoses.
    Use common service equipment: hose clamp removal and installation tool.

    

87. 87
    Install the engine lifting equipment.

    

88. 88
    Remove the engine from the engine stand.
    Use common service equipment: Engine Stand

    

89. 89
    • Use the universal pulley holder (such as OTC 4754 or equivalent). Install the flywheel and new bolts. Using the universal pulley holder, tighten the new crankshaft pulley bolts in the sequence shown.
      Torque:
      Stage 1: 37 lb-ft (50 N·m)
      Stage 2: 59 lb-ft (80 N·m)
      Stage 3: 83 lb-ft (112 N·m)

    • Remove the universal pulley holder.

    

90. 90
    Using the universal pulley holder, tighten in the sequence shown, 2 turns at a time.
    Torque: 21 lb-ft (29 N·m)