Section 1034 (Engine - 3.5L GTDI): Assembly: Engine

• Tighten to 35 lb.in (4 Nm)

• Select the crankshaft main bearings for each crankshaft journal.

• Record the code that is on the cylinder block face.

• Record the code that is on the crankshaft flange.

• The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.

Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4.

• 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 block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.

• As an example, if the engine block code letter is "M" and the crankshaft code letter is "M", the correct bearing grade for this main bearing is a "2" for the upper bearing and a "2" for the lower bearing.

• Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.

Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3.

• Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.

• Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing.

• As an example, if the engine block code letter is "N" and the crankshaft code letter is "H", the correct bearing grade for this main bearing is "2".

• Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.

Using the original connecting rod cap bolts, install the connecting rod caps and bolts.

• Stage 1: Tighten to 17 lb.ft (23 Nm)

• Stage 2: Tighten to 32 lb.ft (43 Nm)

• Stage 3: Tighten an additional 90 °

• Remove the bolts and the rod cap.

• Discard the bolts.

Lubricate the upper crankshaft main bearings with clean engine oil and install in the cylinder block.

Install the crankshaft.

Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.

Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.

Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.

Tighten the main bearing bolts.

• Stage 1: Tighten to 24 lb.ft (33 Nm)

• Stage 2: Tighten an additional 135 °

• Stage 1: Tighten to 33 lb.ft (45 Nm)

• Stage 2: Tighten an additional 90 °

• 1.
  
  Position the crankshaft to the rear of the cylinder block.

• 2.
  
  Using the Holding Fixture with Dial Indicator Gauge, zero the Dial Indicator Gauge.

• 3.
  
  Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play.

• Prepare the connecting rod and cap

• Insert the new bolts in the rod cap.

• Insert the upper and lower rod bearings into the rod and cap.

• 1.
  
  Center line of the piston parallel to the wrist pin bore.

• 2.
  
  Upper compression ring gap location.

• 3.
  
  Upper oil control segment ring gap location.

• 4.
  
  Lower oil control segment ring gap location.

• 5.
  
  Expander ring and lower compression ring gap location.

Using the Piston Ring Compressor, install the piston and connecting rod assemblies. Repeat until all 6 piston assemblies are installed.

Install the connecting rod cap and the new bolts.

• Stage 1: Tighten to 17 lb.ft (23 Nm)

• Stage 2: Tighten to 32 lb.ft (43 Nm)

• Stage 3: Tighten an additional 90 °

• Stage 2: Tighten to 18 lb.ft (24 Nm)

• Stage 3: Tighten an additional 180 °

Apply a 3 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.

• Tighten to 89 lb.in (10 Nm)

• Tighten to 89 lb.in (10 Nm)

• Tighten to 89 lb.in (10 Nm)

Apply a 3 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the oil pan.

Apply a 5.5 mm (0.21 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.

• Stage 1: Tighten to 27 lb.in (3 Nm)

• Stage 2: Loosen: 180 °

• Tighten to 27 lb.in (3 Nm)

• Stage 1: Tighten bolts 1 through 14 to 18 lb.ft (24 Nm)

• Stage 2: Tighten bolt 10 an additional 90 °

• Stage 2: Tighten bolts 15 and 16 to 89 lb.in (10 Nm)

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

• Stage 2: Tighten an additional 45 °

• 177 lb.in (20 Nm)

Install the cylinder head and the new bolts.

• Stage 1: Tighten to 177 lb.in (20 Nm)

• Stage 2: Tighten to 26 lb.ft (35 Nm)

• Stage 3: Tighten an additional 90 °

• Stage 4: Tighten an additional 90 °

• Stage 5: Tighten an additional 45 °

• Tighten to 89 lb.in (10 Nm)

Install the cylinder head and the new bolts.

• Stage 1: Tighten to 177 lb.in (20 Nm)

• Stage 2: Tighten to 26 lb.ft (35 Nm)

• Stage 3: Tighten an additional 90 °

• Stage 4: Tighten an additional 90 °

• Stage 5: Tighten an additional 45 °

• Tighten to 89 lb.in (10 Nm)

Install the valve tappets.

• Tighten to 89 lb.in (10 Nm)

Position the crankshaft dowel pin in the 9 o'clock position.

Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral position as shown

Position the RH camshaft seals gaps as shown.

Install the camshaft caps, oil tube and the bolts.

• Stage 1: Tighten to 71 lb.in (8 Nm)

• Stage 2: Tighten an additional 45 °

• Stage 1: Tighten to 71 lb.in (8 Nm)

• Stage 2: Tighten an additional 45 °

Using a feeler gauge confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Check .

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

• Stage 2: Tighten an additional 45 °

Install the Camshaft Holding Tool.

Install the Chain Tensioner Hold Down Tool.

Position the RH VCT units and secondary timing chain onto the camshafts by aligning the holes in the VCT units with the dowel pins in the camshafts.

• Stage 1: Tighten to 30 lb.ft (40 Nm)

• Stage 2: Loosen: 1 turn(s)

• Stage 3: Tighten to 18 lb.ft (25 Nm)

• Stage 4: Tighten an additional 180 °

Remove the Chain Tensioner Hold Down Tool.

Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral position as shown.

Position the LH camshaft seals gaps as shown.

Install the camshaft caps, oil tube and the bolts.

• Stage 1: Tighten to 71 lb.in (8 Nm)

• Stage 2: Tighten an additional 45 °

• Stage 1: Tighten to 71 lb.in (8 Nm)

• Stage 2: Tighten an additional 45 °

Using a feeler gauge confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Check .

Install the Camshaft Holding Tool.

Install the Chain Tensioner Hold Down Tool.

Position the LH VCT units and secondary timing chain onto the camshafts by aligning the holes in the VCT units with the dowel pins in the camshafts.

• Stage 1: Tighten to 30 lb.ft (40 Nm)

• Stage 2: Loosen: 1 turn(s)

• Stage 3: Tighten to 18 lb.ft (25 Nm)

• Stage 4: Tighten an additional 180 °

Remove the Chain Tensioner Hold Down Tool.

• Tighten to 89 lb.in (10 Nm)

Install the timing chain with the colored links aligned with the timing marks on the VCT units and the crankshaft sprocket.

• Tighten to 89 lb.in (10 Nm)

• 1.
  
  Release the ratchet detent.

• 2.
  
  Using a soft-jawed vise, compress the ratchet plunger.

• 3.
  
  Align the hole in the ratchet plunger with the hole in the tensioner housing and install a lockpin.

• Install the timing chain tensioner and the bolts.
  • Tighten to 89 lb.in (10 Nm)

• Remove the lockpin.

• As a post-check, verify correct alignment of all timing marks.

• There are 48 links in between the RH intake VCT unit colored link (1) and the LH intake VCT unit colored link (2).

• There are 35 links in between LH intake VCT unit colored link (2) and the 2 crankshaft sprocket links (3).

Install the VCT oil control solenoids and the bolts.

• Stage 1: Tighten to 71 lb.in (8 Nm)

• Stage 2: Tighten an additional 20 °

• Stage 1: Tighten to 71 lb.in (8 Nm)

• Stage 2: Tighten an additional 45 °

Using the special tools, install the front cover to coolant pipe seal.

• Apply a 3.0 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.

• Apply a 5.5 mm (0.21 in) bead of Motorcraft ® 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 places as indicated.

Install the engine front cover and the bolts.

• Tighten to 27 lb.in (3 Nm)

• Stage 1: Tighten bolts 1 thru 21 to 89 lb.in (10 Nm)

• Stage 2: Tighten bolts 1 thru 20 to 18 lb.ft (24 Nm)

• Stage 3: Tighten bolt 21 to 177 lb.in (20 Nm)

• Stage 4: Tighten bolt 21 an additional 90 °

• Stage 5: Tighten bolt 22 to 89 lb.in (10 Nm)

• Stage 6: Tighten bolt 22 an additional 45 °

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

• Stage 2: Tighten an additional 45 °

Install the CMP sensors and the bolts.

• Tighten to 89 lb.in (10 Nm)

If removed, using the special tools, install the spark plug tube seals.

If removed, using the special tools, install the VCT oil control solenoid seals.

Apply an 8 mm (0.31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to- RH cylinder head joints.

• Tighten to 89 lb.in (10 Nm)

Apply an 8 mm (0.31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

• Tighten to 89 lb.in (10 Nm)

• Install the CMP sensors and the bolts.
  • Tighten to 89 lb.in (10 Nm)

• Install all of the coil-on-plugs and the bolts.
  • Tighten to 62 lb.in (7 Nm)

• Install the engine wiring harness attach all of the wiring harness retainers.

• Connect the coil-on-plug electrical connectors.

• Connect the CMP sensor electrical connectors.

• Connect the VCT sensor electrical connectors.

• Attach the wiring harness retainers.

• Connect the coil-on-plug electrical connectors.

• Connect the VCT sensor electrical connectors.

• Install the oil level indicator.

• Install the CKP sensor and bolt.
  • Tighten to 89 lb.in (10 Nm)

• Connect the CKP sensor electrical connector.

• Attach the wiring harness grommet to the cylinder block.

• Install the stud bolt.
  • Tighten to 89 lb.in (10 Nm)

• Tighten to 89 lb.in (10 Nm)

• Install the ground wire and stud bolt.
  • Stage 1: Tighten to 89 lb.in (10 Nm)
  • Stage 2: Tighten an additional 20 °

• Attach the wiring harness retainer and if equipped, install the nut.
  • Tighten to 89 lb.in (10 Nm)

• Connect the CMP sensor electrical connectors.

• Connect the RH and LH fuel charge harness electrical connectors.

• Connect the fuel pressure sensor electrical connector.

• Connect the KS electrical connector.

• Install the ground wire and stud bolt.

• Connect the CHT sensor electrical connector and wiring harness retainer.

Clean the surface and apply an 8mm bead of sealer.

Install the vacuum pump and the bolts.

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

• Stage 2: Tighten an additional 45 °

• Tighten to 89 lb.in (10 Nm)

• Stage 1: Tighten to 142 lb.in (16 Nm)

• Stage 2: Tighten an additional 180 °

• Tighten to 30 lb.ft (40 Nm)

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

• Stage 2: Tighten an additional 45 °

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

• Stage 2: Tighten an additional 45 °

Install the new oil cooler and the bolt.

• Tighten to 43 lb.ft (58 Nm)

• NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.

  Install a new O-ring seal.

• Install a new gasket.

• 1.
  
  Install the LH turbocharger and the bolts.
  • Tighten to 24 lb.ft (32 Nm)

• 2.
  
  Install the oil return tube bolt.
  • Stage 1: Tighten to 71 lb.in (8 Nm)
  • Stage 2: Tighten an additional 30 °

• 3.
  
  Install the coolant/oil tube assembly bolt.
  • Stage 1: Tighten to 71 lb.in (8 Nm)
  • Stage 2: Tighten an additional 30 °

• Tighten to 159 lb.in (18 Nm)

• NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.

  Install a new O-ring seal.

• Install a new gasket.

• 1.
  
  Install the RH turbocharger and the bolts.
  • Tighten to 24 lb.ft (32 Nm)

• 2.
  
  Install the oil return tube bolt.
  • Stage 1: Tighten to 71 lb.in (8 Nm)
  • Stage 2: Tighten an additional 30 °

• 3.
  
  Install the coolant/oil tube assembly bolt.
  • Stage 1: Tighten to 71 lb.in (8 Nm)
  • Stage 2: Tighten an additional 30 °

• Tighten to 159 lb.in (18 Nm)

• 1.
  
  Install the high-pressure fuel tube then tighten the flare nuts.
  • Stage 1: Tighten to 133 lb.in (15 Nm)
  • Stage 2: Tighten an additional 45 degrees or 50 Nm (37 lb-ft), whichever comes first.

• 2.
  
  Install the high pressure fuel tube bracket bolt.
  • Stage 1: Tighten to 89 lb.in (10 Nm)
  • Stage 2: Tighten an additional 45 degrees.

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

• Stage 2: Tighten an additional 45 °

• Install new O-ring seals.

• Install the coolant pipe.

• Stage 1: Tighten to 71 lb.in (8 Nm)

• Stage 2: Tighten an additional 45 °

• 1.
  
  Install the coolant pump pulley and the bolts.
  • Tighten to 18 lb.ft (24 Nm)

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

• Stage 1: Tighten to 89 lb.ft (120 Nm)

• Stage 2: Loosen: 1 turn(s)

• Stage 3: Tighten to 37 lb.ft (50 Nm)

• Stage 4: Tighten an additional 90 °

• Attach the vacuum hose retainers to the valve covers.

• Connect the electrical connector to the vacuum solenoid.

• Connect the vacuum hoses to the turbochargers.

• Tighten to 63 Nm (46 lb-ft).

• Tighten to 63 Nm (46 lb-ft).

Install the Right Front Lift Eye and the bolts.

Install the flexplate and the bolts.

• Tighten to 59 lb.ft (80 Nm)