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Engine Printable View

303-01 Engine 2003 Aviator

ASSEMBLY Procedure revision date: 02/15/2005

Special Tool(s)

Guides, Connecting Rod 303-442 (T93P-6136-A)

Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)

Installer, Crankshaft Front Oil Seal 303-635

Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)

Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)

Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)

Compressor, Valve Spring 303-452 (T93P-6565-AR)

Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)

Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent

Holding Tool, Crankshaft 303-448 (T93P-6303-A)

Lifting Bracket Engine (2 Req'd) 303-D087 (D93P-6001-A1)

Strap Wrench 303-D055 (D85L-6000-A)

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2/4/2013http://www.fordtechservice.dealerconnection.com/vdirsnet/Workshop_gsi/Workshop_conte...

NOTE: Before assembling engine components, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

All vehicles

1. NOTE: RH shown, LH similar.

Install the drain plugs into the engine block.

2. Install the upper main bearings into the cylinder block and the lower main bearing into the crankshaft main bearing caps. Lubricate the main bearings with clean engine oil.

3. Install the crankshaft into the cylinder block.

4. NOTICE: Make sure the coated side of the thrust washer, with the 5-mm wide oil grooves, faces the crankshaft thrust surface.

Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.

5. Loosely install the main caps and the bolts.

6. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.

Material

Item Specification

SAE 5W-20 Super Premium Synthetic Blend Engine Oil XO-5W20-QSP or equivalent

WSS-M2C153-H

Metal Surface Cleaner F4AZ-19A536-RA or equivalent

WSE-M5B392-A

Silicone Gasket and Sealant F7AZ-19554-EA or equivalent

WSE-M4G323-A4

Silicone Brake Caliper Grease and Dielectric Compound XG-3 or equivalent

ESE-M1C171-A

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7. Tighten bolts 1-20 in the sequence shown in four stages.

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

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


� Stage 4: Tighten an additional 90 degrees.

8. Install and tighten the cross-mounted bolts in two stages.



9. Check the crankshaft end play. For additional information, refer to Section 303-00.

10. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: Make sure that the piston arrow is facing forward.

NOTE: Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine oil.

Using the special tool, push the pistons through the top of the cylinder block.

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11. NOTICE: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.

NOTE: Make sure the crankshaft is at top dead center (TDC).

Using the special tool, install the connecting rod assemblies.

12. NOTE: The rod bearing cap bolts are torque-to-yield. Install new bolts each time they are serviced.

Install the connecting rod bearing caps and bolts and tighten in three stages.




13. Check the connecting rod bearing clearance. For additional information, refer to Section 303-00.

14. Install the spacers and the windage tray.

15. Install and tighten the oil pump screen spacer.

16. Position the oil pump, and tighten the bolts in the sequence shown.

17. NOTE: Install a new O-ring if necessary.

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Install the oil pump screen cover and tube.

18. Install the cylinder head gaskets.

19. NOTE: LH shown; RH similar.

NOTE: Lubricate the bolt heads and threads. Use clean engine oil.

Install the LH and RH cylinder heads and tighten the bolts in six stages in the sequence shown.



� Stage 3: Loosen the bolts a minimum of one full turn.




Engines with ratcheting timing chain tensioner

20. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using an edge of a vise.

21. Using a small screwdriver or pick, push back and hold the ratchet mechanism.

22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

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23. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.

� Remove the tensioner from the vise.

Engines with non-ratcheting timing chain tensioners

24. Compress the tensioner plunger, using a vise.

25. Install a retaining clip on the tensioner to hold the plunger in during installation.

26. Remove the tensioner from the vise.

All engines

27. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.

28. Install the timing chain guides.

29. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is at approximately the 11 o'clock position.

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30. NOTICE: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

Using the special tool, position the crankshaft.

� Remove the special tool.

31. Install the crankshaft sprocket with the flange facing forward.

32. Install the LH and RH timing chains onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.

33. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

Position the LH and RH timing chains on the camshaft sprockets. Make sure the copper-colored links align with the camshaft sprocket timing marks.

34. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the bolts.

Engines with ratcheting timing chain tensioners

35. Remove the retaining clip from the timing chain tensioners.

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36. Remove the retaining clips from the timing chain tensioners.

All vehicles

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

38. Position the crankshaft sensor ring on the crankshaft.

39. Install the oil pan and gasket and loosely install the bolts.

40. Tighten the bolts in the sequence shown.

� Tighten to 20 Nm (15 lb-ft).

� Rotate an additional 60 degrees.

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41. Install the drain plug.

42. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.

Apply silicone gasket and sealant in the locations shown.

43. Install the engine front cover and tighten the bolts in the sequence shown.

Item Part Number Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53





6 W706508 Stud, Hex Shldr Pilot, M8 x 1.25 x 50 — M6 x 1 x 10

7 N808586 Stud and Washer, Hex-Head Pilot, M8 x 1.25 x 60 — M6 x 1 x 26




11 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 — M8 x 1.25 x 26

12 W706560 Stud, Hex-Head Pilot, M8 x 1.25 x 65 — M8 x 1.25 x 16

13 W706560 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 — M8 x 1.25 x 26

14 W706560 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 — M8 x 1.25 x 26

15 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 — M8 x 1.25 x 26

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44. Install the four oil pan bolts and tighten in three stages in the sequence shown.

� Stage 1: Tighten to 2 Nm (18 lb-in).



45. Using the special tool, install the 32 roller followers.

46. NOTE: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.

Apply silicone gasket and sealant in the locations shown.

47. NOTE: RH shown; LH similar.

Install the valve covers and tighten the bolts in the sequence shown.

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48. Install the belt idler pulley.

49. Lubricate the front oil seal and the engine front cover with clean engine oil.

50. Using the special tools, install the front oil seal.

51. Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.

52. Using the special tool, install the crankshaft pulley.

53. Install the special tool.

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54. Install the bolt and washer. Tighten the bolt in four stages.


� Stage 2: Loosen the bolt one full turn.



55. NOTE: Lubricate the O-ring seal with clean engine coolant. Use the same type of coolant that was drained from the system.

Install the coolant pump and the bolts.

56. Install the coolant pump pulley.

57. Install the A/C compressor and the bolts.

58. Install the power steering pump and the three bolts.

59. Install the oil filter adapter.

� Position the gasket and the oil filter adapter.

� Install and tighten the bolts.

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60. NOTE: LH shown, RH similar.

Install the LH and RH engine mounts.

61. NOTE: Install a new O-ring and lubricate with clean engine oil.

Install the oil level indicator tube.

� Install the oil level indicator tube in the engine block.

� Install the fasteners and tighten to 10 Nm (89 lb-in).

62. NOTE: LH shown; RH similar.

Install the exhaust manifolds. 1. Install new exhaust manifold gaskets. 2. Install the exhaust manifolds. 3. Install the 16 nuts.

63. Install the bolts and the knock sensors (KS).

64. Install the bolt and the coolant bypass tube.

65. NOTE: Upper intake shown removed for clarity.

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Install the upper and lower intake.

� Tighten all fasteners in the sequence shown to 10 Nm (89 lb-in).

66. Install the upper-to-lower intake bracket and the nuts.

67. Install the coolant hose retainers on the RH valve cover.


Install the engine lifting eyes.

69. Install the eight ignition coils.

70. Install the crossover tube. 1. Install the crossover tube and the nuts. 2. Connect the coolant hose.

71. Install the generator and the bolts.

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72. Install the generator support bracket and the bolts.

73. Install the accessory drive belt. For additional information, refer to Section 303-01.

74. Install the coolant bypass-to-thermostat housing hose.

75. Install the upper radiator hose.

76. Position the engine wiring harness on the engine.

77. Connect the A/C compressor and the crankshaft position (CKP) sensor electrical connectors.

78. Connect the engine coolant temperature (ECT) sensor electrical connector.

79. Connect the two harness retainers to the RH valve cover studs.

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80. Connect the throttle position (TP) sensor and the idle air control (IAC) sensor electrical connectors.

81. Connect the RH radio interference capacitor electrical connector and the pin-type retainer.

82. Install the positive crankcase ventilation (PCV) tube.

83. Connect the PCV electrical connector.

84. Connect the cylinder head temperature (CHT) sensor electrical connector and the two pin-type retainers.

85. Connect the exhaust gas recirculation (EGR) system module tube to the exhaust manifold.

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86. Connect the intake manifold runner control (IMRC) electrical connector.

87. Connect the wiring harness retainer to the stud on the cylinder head.

88. Connect the KS electrical connector and the pin-type retainer.

89. Connect the pin-type retainers to the back of the engine in the locations shown.

90. Connect the oil pressure sensor electrical connector.

91. Connect the camshaft position (CMP) sensor electrical connector and the two retainers to the valve cover.

92. Install the fuel charging wiring harness retainers to the fuel injection supply manifold.

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93. Connect the eight fuel injector electrical connectors.

94. Connect the radio interference capacitor electrical connector.

95. Connect the eight ignition coils electrical connectors.


Install the RH and LH coil covers.

97. Position the vacuum harness and connect it to the intake manifold.

98. Connect the electrical connector and the vacuum hose to the fuel pressure sensor.

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99. Install the battery cable harness and the bolt to the RH engine mount.

100. Connect the two retainers to the A/C compressor.

101. Connect the two retainers to the engine front cover studs.

102. Connect the electrical connector and the battery cable to the alternator.

103. Connect the battery cable harness ground.

104. Position the power steering reservoir and install the two bolts and the pin-type retainer.

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105. Install the remaining bolt and the hose to the power steering reservoir.

106. Remove the engine from the stand.

107. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.

Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer plate sealing surface. Also apply a bead of silicone gasket and sealant at the junction where the cylinder block, oil pan and rear oil seal retainer plate meet.

108. Install the rear oil seal retainer plate. Tighten the bolts in the sequence shown in four stages.

� Stage 1: Tighten bolts 1-6 to 10 Nm (89 lb-in).

� Stage 2: Hand-tighten bolts 7 and 8.

� Stage 3: Tighten bolts 7 and 8 to 20 Nm (15 lb-ft).

� Stage 4: Tighten bolts 7 and 8 an additional 60 degrees.

109. Using the special tools, install the crankshaft rear main seal.

110. Using the special tool, install the crankshaft oil slinger.

111. Install the spacer plate and the flexplate.

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