Special Tool(s) / General Equipment
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100-002
(TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge |
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300-OTC1819E 2,200# Floor Crane, Fold Away |
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303-103
(T74P-6375-A)
Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F |
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303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit TKIT-2010B-FLM TKIT-2010B-ROW |
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303-1502 Lifting Device Engine TKIT-2012A-FL TKIT-2012A-ROW |
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303-1532 Installer, Camshaft Seal TKIT-2010B-FLM TKIT-2010B-ROW |
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303-1550 Alignment Tool, Crankshaft Vibration Damper TKIT-2012A-FL TKIT-2012A-ROW |
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303-1552 Alignment Tool, Camshaft TKIT-2012A-FL TKIT-2012A-ROW |
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303-1567 Sizer, Teflon Seal TKIT-2010C-FLM |
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303-175
(T82L-6316-A)
Installer, Crankshaft Vibration Damper TKIT-1982-F |
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303-335
(T88T-6701-A)
Installer, Front Cover Oil Seal TKIT-1988-FLM TKIT-1988-F |
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303-393-02 Adapter for 303-393 TKIT-2012A-FL TKIT-2012A-ROW |
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303-393A Locking Tool, Flywheel TKIT-2012A-FL TKIT-2012A-ROW |
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303-420
(T92P-6701-BH)
Installer, Crankshaft Front Oil Seal TKIT-1992-FLMH/LMH TKIT-1992-LMH/MH |
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303-748 Locking Tool, Crankshaft TKIT-2010B-FLM TKIT-2010B-ROW |
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310-205 Fuel Injector Brush |
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310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM |
Feeler Gauge | |
M6 Tap | |
Hose Clamp Remover/Installer | |
Piston Ring Compressor |
Materials
Name | Specification |
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Motorcraft® Threadlock 262 TA-26 |
WSK-M2G351-A6 |
Motorcraft® High Performance Engine RTV Silicone TA-357 |
WSE-M4G323-A6 |
Flange Sealant CU7Z-19B508-A |
WSS-M2G348-A11 |
Motorcraft® Metal Surface Prep Wipes ZC-31-B |
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Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil XO-5W20-Q1SP |
WSS-M2C945-B1 |
Motorcraft® Orange Concentrated Antifreeze/Coolant VC-3-B |
WSS-M97B44-D |
Flange Sealant - Anaerobic Loctite® 51031 |
WSK-M2G348-A7 |
Motorcraft® Metal Brake Parts Cleaner PM-4-A, PM-4-B |
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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, can cause engine failure.
NOTE: Refer to exploded views in Description and Operation.
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NOTE: Mounted flush and finger tight.
Mount the main bearing beam flush with the block and install the bolts finger-tight.![]() |
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NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
NOTE: Use the original connecting rod cap bolts.
Using the original bolts, install the connecting rod caps and the bolts in 3 stages.![]() |
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NOTE: 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.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Lubricate with clean engine oil and install crankshaft main bearings.![]() |
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Lubricate with clean engine oil and install the main beam bearings.![]() |
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NOTE: Lubricate the main bearing beam bolts threads with clean engine oil.
Install the main bearings beam and the bolts and tighten the bolts in sequence shown in 4 stages.![]() |
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NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.
Lubricate with clean engine oil and install the connecting rod bearings.![]() |
NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper side.
NOTE: Arrows faces the front of the engine.
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NOTE: Using a connecting rod installer will unsure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Make sure the piston arrows on top is facing toward the front of the engine.
Using the Piston ring Compressor, lubricate with clean engine oil and install the pistons.![]() |
NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
NOTE: Use new connecting rod caps bolts.
Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.![]() |
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NOTE: Only rotate the crankshaft clockwise direction.
Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC.![]() |
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NOTE: Make sure that the locating dowels remain installed.
Inspect the oil pump locating dowels for damage and correct installation.![]() |
NOTE: Only tighten the bolts finger tight at this stage.
Install the oil pump and follow the steps below. Hand start the bolts.![]() |
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NOTE: New crankshaft rear seal is supplied with an alignment sleeve which must be removed after installation.
NOTE: Do not remove the alignment sleeve from the crankshaft rear seal prior to installation on the crankshaft.
Align the crankshaft rear seal and alignment sleeve on the crankshaft and push the crankshaft rear seal off the alignment sleeve onto the crankshaft without stopping until the crankshaft rear seal meets the cylinder block.![]() |
NOTE: The O-ring seal is to be reused unless damaged.
Inspect the oil pump screen and pickup tube O-ring seal.![]() |
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NOTE: The use of the two studs will aid on the alignment of the oil pan.
Two M8x20 studs.![]() |
NOTE: The component must be installed within 5 minutes of applying the sealant.
Apply a 3.5 mm (0.137 in) bead of silicone sealant.![]() |
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NOTE: Using a straight edge, align the back of the oil pan to the cylinder block.
Install the oil pan bolts finger tight.![]() |
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NOTE: Only rotate the crankshaft clockwise direction.
Verify the crankshaft balance weight is up against the crankshaft locking tool.![]() |
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NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Make sure that the mating faces are clean and free of foreign material.![]() |
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NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
NOTE: Make sure that no fluids are present in the cylinder head bolt threaded bores.
Install the cylinder head and the bolts finger-tight and then tighten the bolts in sequence shown in 5 stages.![]() |
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NOTICE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance, follow the next 12 steps exactly or serious damage to the engine may occur. If the original parts are being installed it is not necessary to check the valve clearance so proceed to step 65.
Place a paint mark on the crankshaft at the 12 o'clock position.![]() |
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NOTE: Rotating the crankshaft will position all of the pistons below the deck of the cylinder block and allow the camshafts to be installed and the valve clearance checked without the possibility of damage to the valves or pistons.
Using the crankshaft bolt and washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position.![]() |
NOTICE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.
NOTICE: Make sure that the camshafts and camshaft bearing caps are installed in their original locations or damage to the engine may occur.
NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: Apply clean engine oil to the bearing surfaces of the camshafts, camshaft bearing caps and the VCT bridge.
Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head.![]() |
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NOTE: Select tappets using this formula: ideal tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
NOTE: The nominal clearance is 0.0112 in ( .285 mm) for intake and 0.0167 in ( .425 mm) for exhaust.
NOTE: The acceptable clearances after being fully installed is 0.009 –0.013 in ( .24 –.33 mm) for intake and 0.015 –0.019 in ( .38 –.47 mm) for exhaust.
NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.
Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps in sequence shown.![]() |
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NOTE: Rotating the crankshaft will position the engine at TDC and allow you to install the camshafts in the same position as noted during the disassembly.
Rotate the crankshaft clockwise 90 degrees so the crankshaft contacts the Timing Peg, Crankshaft TDC 303-748.![]() |
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NOTE: Verify the crankshaft contacts the Timing Peg and the engine is still at TDC.
Install Special Service Tool: 303-393A Locking Tool, Flywheel. , 303-393-02 Adapter for 303-393.![]() |
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NOTE: The VCT bridge must be installed within 5 minutes of applying the gasket maker.
Apply a 2.0 mm bead of flange sealant.![]() |
NOTICE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.
NOTICE: Make sure that the camshafts and camshaft bearing caps are installed in their original locations or damage to the engine may occur.
NOTE: Make sure that new bolts are installed.
Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head.![]() |
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NOTE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon to align the camshafts.
Install Special Service Tool: 303-1552 Alignment Tool, Camshaft.![]() |
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NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Install the VCT units new bolts.![]() |
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NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Tighten an additional:![]() |
NOTE: The special tool can only be installed if the valve timing is correct.
Install Special Service Tool: 303-1552 Alignment Tool, Camshaft.![]() |
NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.
NOTE: If the VCT unit bolts are removed again, they must be replaced.
If the special tools cannot be installed, repeat the adjustment according to the preceding steps.![]() |
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NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Install the VCT unit caps.![]() |
NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.
Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit.![]() |
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WARNING:
The timing belt tensioner spring is under load. Extra
care must be taken at all times when handling the tensioner. Failure to
follow this instruction may result in personal injury.
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NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: Click here to view a video version of installing the crankshaft front seal.
View - English
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NOTICE: If the crankshaft front seal is rolled during positioning, do not use the special tool to install or an oil leak will occur.
If any part of the crankshaft front seal inner lip is rolled, remove and reposition the seal. Also make sure the seal spring is properly positioned on the seal.![]() |
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NOTE: Before installation, clean and inspect the sprocket for any damage. If damage is evident, replace the sprocket. If no damage, the sprocket is to be reused.
Install the timing belt sprocket.![]() |
NOTE: Install the timing belt in the following sequence.
Install the timing belt in the following sequence.![]() |
WARNING:
The timing belt tensioner spring is under load. Extra
care must be taken at all times when handling the tensioner. Failure to
follow this instruction may result in personal injury.
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NOTE: Make certain the special tools that secure the flywheel from rotating are still installed prior to performing this step. Failure to secure the flywheel may cause misalignment of the crankshaft pulley to the crankshaft resulting in driveability concerns.
Tighten the crankshaft pulley bolt in 4 stages.![]() |
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NOTE: Only rotate the crankshaft in a clockwise direction.
Rotate about 1 3/4 turns.![]() |
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NOTE: Only rotate the crankshaft in a clockwise direction.
Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC.![]() |
NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.
NOTE: It may necessary to rotate the camshafts slightly to install the special tool.
If the special tool cannot be installed, repeat the adjustment according to the preceding steps.![]() |
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NOTE: There are different length of bolts noted in disassembly.
Install the engine mount bracket and the bolts.![]() |
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NOTICE: Do-not use a metal brush; damage to sealing area will result in leaks.
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NOTICE: Do-not use a metal brush; damage to sealing area will result in leaks.
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NOTE: Lubricate the spigot with clean engine oil.
Inspect the crankcase vent oil separator gasket. Lubricate the crankcase vent oil separator O-ring seal.![]() |
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NOTE: The head of the KS should not touch any other component.
NOTE: The LH KS must be at the 10 o'clock position and the RH KS must be at the 2 o'clock position.
Install the KS, bolts and attach the retainer.![]() |
NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Install the new oil cooler and the retainer.![]() |
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material.![]() |
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material.![]() |
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material.![]() |
NOTE: The components must be installed within 5 minutes of applying the sealant.
Apply a 1.5 mm (0.059 in) bead of sealant.![]() |
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NOTE: Use a new O-ring seal.
Install the a new O-ring seal, high-pressure fuel pump drive unit and the bolts and tighten in sequence shown in 3 stages.![]() |
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NOTE: The components must be installed within 5 minutes of applying the sealant.
Apply a 1.5 mm (0.059 in) bead of sealant.![]() |
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NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.
NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
NOTE: Do not use compressed air to clean the tip of the fuel injector.
NOTE: Do not use a brush to clean the tip of the fuel injector.
Clean the fuel injector bores.![]() |
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NOTICE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
NOTICE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
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NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.
NOTICE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
NOTE: Make sure that new lower fuel injector Teflon® seals are installed.
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NOTICE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
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NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
Lubricate and install the fuel injector O-ring seal and the washer.![]() |
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NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.
Install the fuel injectors.![]() |
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
NOTE: Take extra care when handling the components.
NOTE: Only tighten the 4 fuel rail bolts finger tight at this stage.
Apply a force of 90 lb (400 N) to 224.81 lb (1,000 N) on the fuel rail assembly uniformly above the coil mounting brackets in a direction parallel to the axis of the injectors. This will engage all 4 injector combustion seals into the cylinder head allowing the injectors to seat.![]() |
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NOTE: The cam lobe for the fuel injection pump must be at BDC for the fuel injection pump installation.
Lubricate and install the high-pressure fuel pump tappet.![]() |
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NOTE: Make sure that 2 new fuel injection pump mounting bolts are installed.
NOTE: Install all the bolts finger tight before final tightening.
Install the fuel injection pump and loosely install the 2 fuel injection pump bolts, alternately tighten each bolt one half of a revolution until seated.![]() |
NOTE: Make sure that a new component is installed.
NOTE: Calculate the correct torque wrench setting for the following torque. Refer to Torque Wrench Adapter Formulas.
Install the high-pressure fuel tube and tighten the flare nuts in 3 stages.![]() |
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NOTE: The O-ring seals are to be reused unless damaged.
Lubricate the VCT oil control solenoid O-ring seal.![]() |
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NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
Inspect the intake manifold gaskets.![]() |
NOTE: Apply threadlock 262 to the intake manifold bolt threads.
NOTE: Make sure the KS wiring connectors are properly routed and not trapped behind the intake manifold while installing the intake manifold.
Install the intake manifold and tighten the bolts in sequence shown.![]() |
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NOTE: Make sure the mating surfaces are clean and free of foreign material and the thread lock residue is cleaned from stud bolt holes.
Make sure the mating surfaces are clean and free of foreign material and tap on the vacuum pump mounting hole.![]() |
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NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.
NOTE: Install new stud bolts for brake vacuum pump.
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The system detects available parallel parking spaces and steers your vehicle into the space. You control the accelerator, gearshift and brakes. The system visually and audibly guides you into a parallel parking space.
Press the button once to search
for a parking space.