Engine. Assembly

Special Service Tools / General Equipment

	100-002 (TOOL-4201-C) Dial Indicator Holding Fixture
	300-OTC1819E Floor Crane 2200 lb, Folding
	303-103 (T74P-6375-A) Flywheel Holding Tool T74P-77000-A TKIT-2009TS-F
	303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve TKIT-2010B-FLM TKIT-2010B-RYAD
	303-1502 Engine Lifting Device TKIT-2012A-FL TKIT-2012A-RYAD
	303-1532 Installer, Camshaft Seal TKIT-2010B-FLM TKIT-2010B-RYAD
	303-1550 Alignment Tool, Crankshaft Damper TKIT-2012A-FL TKIT-2012A-RYAD
	303-1552 Camshaft Timing Tool TKIT-2012A-FL TKIT-2012A-RYAD
	303-1567 Size, Teflon Seal TKIT-2010C-FLM
	303-175 (T82L-6316-A) Installer, Crankshaft Damper TKIT-1982-F
	303-335 (T88T-6701-A) Installer, Front Cover Seal TKIT-1988-FLM TKIT-1988-F
	303-393-02 Adapter, 303-393 TKIT-2012A-FL TKIT-2012A-RHD
	303-393A Flywheel Locking Tool TKIT-2012A-FL TKIT-2012A-RHD
	303-420 (T92P-6701-BH) Installer, Front Crankshaft Seal TKIT-1992-FLMH/LMH TKIT-1992-LMH/MH
	303-748 Crankshaft Locking Tool TKIT-2010B-FLM TKIT-2010B-RHD
	310-205 Fuel Injector Brush
	310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM
Feeler gauge
Hose Clamp Removal/Installation Tool
Piston Ring Compressor

Materials

NOTICE: Cleanliness is extremely important when repairing the engine. Any foreign material, including material created during the cleaning of gasket surfaces, that enters the oil passages, coolant passages or oil pan may cause engine failure.

1. 1
   Torque: 80 lb-in (9 N·m)

   

2. 2
   • Measure the length in two directions.

   • Record the smallest value for each crankshaft main journal.

   

3. 3
   Install flush and tighten by hand.

   

4. 4
   Torque:
   Stage 1: 22 lb-ft (30 N·m)
   Stage 2: 37 lb-ft (50 N·m)
   Stage 3: 45°
   Stage 4: Tighten additionally: 45°

   

5. 5
   Measure the length at five locations.

   

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

   1. Cylinder Block Bore Diameter

   2. Crankshaft Journal Diameter

   3. Upper bearing color code

   4. Lower bearing color code

   

7. 7

   NOTICE: The connecting rod cap must be installed in the same orientation as marked during disassembly, otherwise engine damage may occur.

   Use the original connecting rod cap bolts.
   Torque:
   Stage 1: 159 lb-in (18 N·m)
   Stage 2: 45°
   Stage 3: Tighten additionally: 45°

   

8. 8
   • Measure the length or distance in two directions.

   • Record the smallest value for each connecting rod.

   

   

9. 9
   • Measure the length in two directions.

   • Record the smallest value for each connecting rod journal.

   

10. 10
    Using the chart, select the connecting rod bearings of the correct size for each crankshaft connecting rod journal.
    

    1. Connecting rod bore diameter

    2. Crankshaft connecting rod journal diameter

    3. Upper bearing color code

    4. Lower bearing color code

    

    

11. 11
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

12. 12
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

13. 13
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

14. 14
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

15. 15
    Install flush.

    

16. 16
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
    Torque:
    Stage 1: 22 lb-ft (30 N·m)
    Stage 2: 37 lb-ft (50 N·m)
    Stage 3: 45°
    Stage 4: Tighten additionally: 45°

    

17. 17
    • 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 must be 0.12-0.43 mm (0.008-0.017 in). If crankshaft end play is outside the specified range, install new components as necessary.

    

18. 18
    Arrows point to the front of the engine.

    

19. 19
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

20. 20
    1. Top compression ring gap location.

    2. Bottom compression ring gap location.

    3. Upper oil control ring rail gap location.

    4. Expander ring gap location.

    5. Lower oil control ring rail gap location.

    

21. 21
    Use common service equipment: Piston Ring Compressor.
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

22. 22

    NOTICE: The connecting rod cap must be installed in the same orientation as marked during disassembly, otherwise engine damage may occur.

    Use new connecting rod cap bolts.
    Torque:
    Stage 1: 159 lb-in (18 N·m)
    Stage 2: 45°
    Stage 3: Tighten additionally: 45°

    

23. 23
    Install the special service tool: 303-748 Crankshaft Locking Tool.

    

24. 24
    Slowly rotate the crankshaft clockwise until the crankshaft balance weight is opposite the crankshaft locking pin. The engine is now at TDC.

    

    

25. 25
    Inspect the oil pump locating dowels for damage and correct installation.

    

26. 26
    Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
27. 27
    Install the oil pump and perform the following steps. Hand-tighten the bolts.
    

    1. Hand-tighten the 2 M6 x 55 mm bolts.

    2. Hand-tighten the 3 M6 x 35 mm bolts.

    3. Hand-tighten the 3 M6 x 25 mm bolts.

    

28. 28
    Tighten the oil pump bolts in the sequence shown in 2 stages.
    Torque:
    Stage 1: Tighten bolts 1, 2, 3 and 6: 18 lb-in (2 N·m)
    Stage 2: Tighten bolts 1 through 8: 97 lb-in (11 N·m)

    

29. 29
    Torque: 84 lb-in (9.5 N·m)

    

30. 30
    Align the rear crankshaft oil seal and the centering sleeve on the crankshaft, and slide the rear crankshaft oil seal off the centering sleeve onto the crankshaft without stopping until the rear crankshaft oil seal contacts the cylinder block.
    Torque:
    Stage 1: 35 lb-in (4 N·m)
    Stage 2: 89 lb-in (10 N·m)

    

31. 31
    Finger tight.

    

32. 32
    Install the special service tool: 303-103 (T74P-6375-A) Flywheel Holding Tool.

    

33. 33
    Torque:
    Stage 1: 133 lb-in (15 N·m)
    Stage 2: 18 lb-ft (25 N·m)
    Stage 3: 22 lb-ft (30 N·m)
    Stage 4: 90°

    

34. 34
    Remove the special service tool: 303-103 (T74P-6375-A) Flywheel Holding Tool.

    

35. 35
    Make sure the crankshaft counterweight is seated against the Crankshaft Locking Tool.

    

36. 36
    Install the special service tools: 303-393-02 Adapter for 303-393, and 303-393A Locking Tool, Flywheel.

    

37. 37

    

38. 38
    Torque: 84 lb-in (9.5 N·m)

    

39. 39
    Clean and prepare the RTV sealing surface.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System — General Information, General Procedures).

    

40. 40
    Clean and prepare the RTV sealing surface.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System — General Information, General Procedures).

    

41. 41
    Clean and prepare the RTV sealing surface.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System — General Information, General Procedures).

    

42. 42
    Install the following components:

    • Two M8x20 studs.

    

43. 43
    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    

44. 44
    Remove the following components:

    • Two M8x20 studs.

    

45. 45

    

46. 46
    Torque:
    Stage 1: 1 - 13: 89 lb-in (10 N·m)
    Stage 2: 1 - 13: 168 lb-in (19 N·m)

    

47. 47

    NOTICE: Do not use metal scrapers, wire brushes, discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that create leak paths. Use a plastic scraper to remove all traces of the cylinder head gasket.

    Material: Motorcraft® Metal Surface Preparation Wipes. / ZS-31-B

    

    

    

48. 48
    Torque:
    Stage 1: 44 lb-in (5 N·m)
    Stage 2: 133 lb-in (15 N·m)
    Stage 3: 26 lb-ft (35 N·m)
    Stage 4: 90°
    Stage 5: Additional tightening: 90°

    

49. 49
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

50. 50
    Material: Motorcraft® Metal Surface Preparation Wipes. / ZS-31-B

    

51. 51
    Material: Motorcraft® Metal Surface Preparation Wipes. / ZS-31-B

    

52. 52

    NOTICE: If any new components (cylinder head, valves, tappets, camshafts) are installed, the valve clearance must be checked. Follow the following 10 steps exactly, otherwise serious engine damage may occur. If original components are installed, it is not necessary to check the valve clearance, so proceed to step 68.

    Paint a mark on the crankshaft at the 12 o'clock position.

    

53. 53
    Remove the special service tools: 303-393A Flywheel Locking Tool, 303-393-02 Adapter, 303-393.

    

54. 54
    Remove the special service tool: 303-748 Crankshaft Locking Tool.

    

55. 55
    Using the crankshaft bolt and washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position.

    

56. 56

    NOTICE: Failure to follow the camshaft tightening procedure may damage the camshafts.

    Evenly tighten the bolts in half-turn increments until the camshaft bearing caps and VCT bridge are seated against the cylinder head.
    Material: Engine Oil — SAE 5W-20 — synthetic engine oil / XO-5W20-Q1SP (WSS-M2C945-B1)
    Torque:
    Step 1: Tighten bolts 1 through 16 to: 62 lb-in (7 N·m)
    Step 2: Tighten bolts 17 through 20 to: 89 lb-in (10 N·m)
    Step 3: Tighten bolts 1 through 16 an additional: 45°
    Step 4: Tighten bolts 17 and 18 an additional: 70°
    Step 5: Tighten bolts 19 and 20 an additional: 53°

    

57. 57
    1. Using the camshaft flats, rotate the camshaft to position the cam lobe on the base circle so that the lobe points away from the tappet.

    2. Using a feeler gauge, measure the clearance of each valve and record its position.
       Use general equipment: Feeler Gauge

    3. Repeat to measure all cam/tappet clearances.

    

58. 58
    • Intake: 0.0118 in (0.3 mm)
    • Exhaust: 0.0157 in (0.4 mm)

    • Intake: 0.010–0.014 in (0.255–0.345 mm)
    • Exhaust: 0.014–0.018 in (0.355–0.445 mm)
59. 59

    NOTICE: Failure to follow the camshaft loosening procedure may damage the camshafts.

    Loosen the camshaft bearing caps sequentially, 2 turns at a time, until all tension is released from the camshaft bearing caps in the sequence shown.

    

60. 60
    Install the special service tool: 303-748 Crankshaft Locking Tool.

    

61. 61
    Rotate the crankshaft clockwise 90 degrees until the crankshaft contacts the timing pin, TDC crankshaft 303-748.

    

62. 62
    If necessary, replace all tappets with the tappets selected during the valve clearance check.

    

63. 63
    Install the special service tools: 303-393A Flywheel Locking Tool, 303-393-02 Adapter, 303-393.

    

    

64. 64
    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    

65. 65

    NOTICE: Failure to follow the camshaft tightening procedure may damage the camshafts.

    Evenly tighten the bolts by half a turn until the camshaft bearing caps and VCT bridge are seated against the cylinder head.
    Torque:
    Stage 1: 1 - 16: 62 lb-in (7 N·m)
    Stage 2: 17 - 20: 89 lb-in (10 N·m)
    Stage 3: 1 - 16: 45°
    Stage 4: 17 and 19: 70°
    Stage 5: 18 and 20: 53°

    

66. 66
    Use the Special Service Tool: 303-1532 Installer, Camshaft Seal.
    Material: Engine Oil — SAE 5W-20 — Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

67. 67
    Install the special service tool: 303-1552 Camshaft Alignment Tool.

    

68. 68
    12 o'clock position.

    

69. 69
    Install the Special Service Tool: 303-1097 Locking Tool, Variable Cam Timing Oil Control Valve.
    Torque: 18 lb-ft (25 N·m)

    

70. 70
    Remove the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

71. 71
    Remove the special service tool: 303-1552 Camshaft Alignment Tool.

    

72. 72
    Tighten an additional:
    Torque: 75°

    

73. 73
    The Special Service Tool can only be installed if the camshaft timing is correct.
    Install the Special Service Tool: 303-1552 Alignment Tool, Camshaft.

    

74. 74
    If the special tools cannot be installed, repeat the adjustment following the previous steps.
    Install the special service tool: 303-1097 Locking Tool, Variable Cam Timing Oil Control Unit.

    

75. 75
    Remove the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

76. 76
    Remove the special service tool: 303-1552 Camshaft Alignment Tool.

    

77. 77
    Torque: 142 lb-in (16 N·m)

    

78. 78
    Install the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

79. 79

    

80. 80
    Torque:
    Stage 1: 53 lb-in (6 N·m)
    Stage 2: 89 lb-in (10 N·m)

    

81. 81
    Torque: 18 lb-ft (25 N·m)

    

82. 82
    Make sure the mating surfaces are clean and free of foreign material.
    Use the Special Service Tools: 303-175 (T82L-6316-A) Installer, Crankshaft Damper. , 303-335 (T88T-6701-A) Installer, Front Cover Seal. , 303-420 (T92P-6701-BH) Installer, Front Crankshaft Seal.
    Material: Engine Oil — SAE 5W-20 — Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

83. 83

    

    

84. 84
    Remove the retaining pin.

    

    

85. 85
    1. Install the special service tool: 303-1550 Alignment Tool, Crankshaft Damper.

    2. Rotate the crankshaft pulley to align the special tool:
       Use the special service tool: 303-1550 Alignment Tool, Crankshaft Damper.

    3. At this stage, finger-tighten.

    4. Using a new bolt, hand-tighten it at this stage.

    

86. 86
    Torque:
    Stage 1: 74 lb-ft (100 N·m)
    Stage 2: 90°
    Stage 3: Wait 2 s
    Stage 4: Tighten an additional: 15°

    

87. 87
    Remove the special service tool: 303-1550 Alignment Tool, Crankshaft Damper.

    

88. 88
    Remove the special service tool: 303-748 Crankshaft Locking Tool.

    

89. 89
    Remove the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

90. 90
    Remove the special service tools: 303-393-02 Adapter for 303-393, and 303-393A Locking Tool, Flywheel.

    

91. 91
    Rotate approximately 1 3/4 turns.

    

92. 92
    Install the special service tool: 303-748 Crankshaft Locking Tool.

    

93. 93
    Slowly rotate the crankshaft clockwise until the crankshaft balance weight is opposite the crankshaft locking pin. The engine is now at TDC.

    

94. 94
    If the special tool cannot be installed, repeat the adjustment according to the previous steps.
    Install the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

95. 95
    Remove the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

96. 96
    Remove the special service tool: 303-748 Crankshaft Locking Tool.

    

97. 97
    Torque: 177 lb-in (20 N·m)

    

98. 98
    Torque: 89 lb-in (10 N·m)

    

99. 99
    Torque: 41 lb-ft (55 N·m)

    

100. 100
     1. Torque: 89 lb-in (10 N·m)

     2. Finger tight.

     3. Finger tight.

     

101. 101
     Torque: 89 lb-in (10 N·m)

     

102. 102
     If equipped with a block heater.
     Torque: 27 lb-in (3 N·m)

     

103. 103
     Torque: 89 lb-in (10 N·m)

     

104. 104
     • Torque: 15 lb-ft (21 N·m)

     • Tighten the fasteners to specification a second time.
       Torque: 15 lb-ft (21 N·m)

     

105. 105
     Torque: 177 lb-in (20 N·m)

     

106. 106
     Torque: 177 lb-in (20 N·m)

     

107. 107
     Torque: 18 lb-ft (25 N·m)

     

108. 108
     • Torque: 18 lb-ft (25 N·m)

     • Tighten the fasteners to specification a second time.
       Torque: 18 lb-ft (25 N·m)

     

109. 109
     Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     

110. 110
     1. Torque: 19 lb-ft (26 N·m)

     2. Torque: 84 lb-in (9.5 N·m)

     

111. 111
     Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     

112. 112
     Torque: 84 lb-in (9.5 N·m)

     

113. 113
     1. Torque: 159 lb-in (18 N·m)

     2. Torque: 21 lb-ft (28 N·m)

     3. Torque: 17 lb-ft (23 N·m)

     

114. 114
     .
     Material: Engine Oil — SAE 5W-20 — Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     

115. 115
     1. Install the bushing into the engine block.

     2. Tighten bolts 1, 2 and 3.
        Torque: 49 lb-in (5.5 N·m)

     3. Tighten bolts 4, 5, 6, 7 and 8.
        Torque: 49 lb-in (5.5 N·m)

     4. Tighten all bolts in sequence.
        Torque: 84 lb-in (9.5 N·m)

     

116. 116
     Torque: 159 lb-in (18 N·m)

     

117. 117
     Material: Motorcraft® PTFE Thread Sealant / TA-24-B (WSK-M2G350-A2)
     Torque: 159 lb-in (18 N·m)

     

118. 118
     Torque: 80 lb-in (9 N·m)

     

119. 119
     Torque: 89 lb-in (10 N·m)

     

120. 120

     NOTICE: A new oil cooler must be installed, otherwise serious engine damage may occur.

     Torque: 41 lb-ft (55 N·m)

     

121. 121
     1. Torque: 150 lb-in (17 N·m)

     2. Torque: 89 lb-in (10 N·m)

     

122. 122

     NOTICE: Do not use metal scrapers, wire brushes, discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that create leak paths.

     Make sure the mating surfaces are clean and free of foreign material.
     Material: Motorcraft® Metal Surface Preparation Wipes / ZC-31-B

     

123. 123

     NOTICE: Do not use metal scrapers, wire brushes, discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that create leak paths.

     Make sure the mating surfaces are clean and free of foreign material.
     Material: Motorcraft® Metal Surface Preparation Wipes / ZC-31-B

     

124. 124

     NOTICE: Do not use metal scrapers, wire brushes, discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that create leak paths.

     Make sure the mating surfaces are clean and free of foreign material.
     Material: Motorcraft® Metal Surface Preparation Wipes / ZC-31-B

     

125. 125
     Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

     

126. 126
     Torque: 89 lb-in (10 N·m)

     

127. 127
     Tighten bolts 1 through 10 as follows:
     Torque:
     Stage 1: 27 lb-in (3 N·m)
     Stage 2: 80 lb-in (9 N·m)
     Stage 3: 97 lb-in (11 N·m)
     Stage 4: Tighten bolts 1, 2, 5, 6, 7, 8, 9 and 10 to: 124 lb-in (14 N·m)

     

128. 128
     Torque: 80 lb-in (9 N·m)

     

129. 129
     Torque: 80 lb-in (9 N·m)

     

     

130. 130
     Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

     

131. 131
     Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

     

132. 132
     Torque:
     Step 1: 44 lb-in (5 N·m)
     Step 2: 80 lb-in (9 N·m)
     Step 3: 89 lb-in (10 N·m)

     

133. 133
     Use the special service tool: 310-205 Fuel Injector Brush.

     

     

134. 134

     NOTICE: Use care when removing the lower Teflon® seals to avoid scratching, nicking or gouging the fuel injectors.

     NOTICE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector, otherwise damage to the injector may occur.

     1. Pull the lower Teflon seal away from the injector.

     2. Carefully cut and discard the lower fuel injector Teflon seals.

     

135. 135

     NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

     1. Use the special service tool: 310-207 Fuel Injector Seal Assembly Installer.

     2. NOTICE: After installing the Teflon® seal, the Teflon® seal guide must be installed onto the fuel injector immediately to avoid excessive expansion of the Teflon® seal.

     3. Using a push tool, seat the Teflon® seals from the Teflon® seal guide and into the groove on the fuel injectors.
        Use the special service tool: 310-207 Fuel Injector Seal Assembly Installer.

     

136. 136

     NOTICE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to expansion of the Teflon® seal.

     1. Some Teflon® seals are massaged with fingers before installing the Teflon® seal sizing tool, which aids in seating the Teflon® seal sizing tool.

     2. Position the Teflon® seal sizing tool with the large opening facing the Teflon® seal. Press and turn the Teflon® seal sizing tool 180 degrees.
        Use special service tool: 303-1567 Teflon® Seal Sizer.

     3. After installing the Teflon® seal sizing tool, check and make sure the Teflon® seal is in the sizing portion of the Teflon® seal sizer tool. After one minute, rotate the Teflon® seal sizing tool back 180 degrees and remove.

     

137. 137

     NOTICE: Use fuel injector O-rings made of special fuel-resistant material. Use of standard O-rings may cause the fuel system to leak. Do not reuse O-rings.

     Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     

138. 138

     

139. 139
     Use only moderate force.

     

140. 140
     Install the 4 bolts, tightening them by hand.
     Torque:
     Step 1: 44 lb-in (5 N·m)
     Step 2: 17 lb-ft (23 N·m)

     

141. 141
     Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     

142. 142
     • Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     • Install the high-pressure fuel pump and loosely install the 2 high-pressure fuel pump bolts, alternately tightening each bolt by one-half turn until seated.
       Torque: 115 lb-in (13 N·m)

     

143. 143
     1. Torque: 62 lb-in (7 N·m)

     2. Torque:
        Step 1: Using a torque adapter, tighten to: 15 lb-ft (21 N·m)
        Step 2: Wait 5 min.
        Step 3: Using a torque adapter, tighten to: 15 lb-ft (21 N·m)

     

     

144. 144
     Torque:
     Step 1: Using a torque adapter, tighten to: 15 lb-ft (21 N·m)
     Step 2: Wait 5 min.
     Step 3: Using a torque adapter, tighten to: 15 lb-ft (21 N·m)

     

     

145. 145
     1. Torque: 89 lb-in (10 N·m)

     2. Torque: 53 lb-in (6 N·m)

     

146. 146
     Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C200-A) (ESE-M1C171-A)

     

147. 147
     Torque: 89 lb-in (10 N·m)

     

148. 148
     Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

     

149. 149
     Torque: 71 lb-in (8 N·m)

     

150. 150
     Torque: 159 lb-in (18 N·m)

     

151. 151

     

152. 152
     Material: Anaerobic Flange Sealant / Loctite® 51031 (WSK-M2G348-A7)

     

153. 153
     1. Torque: 89 lb-in (10 N·m)

     2. Torque: 168 lb-in (19 N·m)

     

154. 154
     Torque: 89 lb-in (10 N·m)

     

155. 155
     1. Torque: 89 lb-in (10 N·m)

     2. Torque: 35 lb-ft (48 N·m)

     3. Torque: 35 lb-ft (48 N·m)

     4. Torque: 35 lb-ft (48 N·m)

     

156. 156
     Torque: 18 lb-ft (25 N·m)

     

157. 157
     Torque: 35 lb-ft (48 N·m)

     

     

158. 158
     Torque: 18 lb-ft (24 N·m)

     

159. 159
     Use common service equipment: hose clamp removal/installation tool.

     

160. 160
     Torque: 89 lb-in (10 N·m)

     

     

     

     

161. 161
     Torque: 71 lb-in (8 N·m)

     

     

     

162. 162
     Torque: 133 lb-in (15 N·m)

     

163. 163
     Use common service equipment: hose clamp removal/installation tool.

     

164. 164
     Use common service equipment: hose clamp removal/installation tool.

     

165. 165
     Use common service equipment: hose clamp removal/installation tool.

     

166. 166
     Use common service equipment: hose clamp removal/installation tool.

     

167. 167
     Use common service equipment: hose clamp removal/installation tool.

     

168. 168
     1. Use common service equipment: hose clamp removal/installation tool.

     2. If equipped.

     

169. 169
     Torque: 133 lb-in (15 N·m)

     

170. 170
     If equipped with a block heater.

     

171. 171
     Install the special service tool: 303-1502 Engine Lifting Device.

     

172. 172
     Install the special service tool: 300-OTC1819E 2200 lb Floor Crane, Folding.

     

173. 173
     Remove from the engine stand.

     

174. 174

     NOTICE: Do not breathe dust and do not use compressed air to blow dust from storage containers or friction components. Remove dust using a method approved by the government. Friction component dust may cause cancer and lung disease. Exposure to potentially hazardous components may occur when dust is generated during repair of friction parts such as brake pads and clutch discs. Exposure may also cause skin, eye and respiratory irritation, may cause allergic reactions and/or may lead to other chronic health effects. If irritation does not go away, seek medical attention or advice. Failure to follow these instructions may result in serious injury.

     Using the clutch alignment tool, center the clutch disc in relation to the clutch pressure plate.

     

175. 175

     NOTICE: Do not breathe dust and do not use compressed air to blow dust from storage containers or friction components. Remove dust using a method approved by the government. Friction component dust may cause cancer and lung disease. Exposure to potentially hazardous components may occur when dust is generated during repair of friction parts such as brake pads and clutch discs. Exposure may also cause skin, eye and respiratory irritation, may cause allergic reactions and/or may lead to other chronic health effects. If irritation does not go away, seek medical attention or advice. Failure to follow these instructions may result in serious injury.

     Torque: 21 lb-ft (29 N·m)