Lincoln Aviator: Engine - 3.0L EcoBoost / Installation - Engine Block Skirt Stiffener

Special Tool(s) / General Equipment

	205-153 (T80T-4000-W) Handle
	303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
	303-1250 Seal Installer, Rear Main TKIT-2006UFFLM
	303-1531 Installer, Front Crank Seal and Damper
	303-1634 Lift Eyes (2) TKIT-2014D-ROW3 TKIT-2014D-FL_ROW
	303-335 (T88T-6701-A) Installer, Front Cover Oil Seal TKIT-1988-FLM TKIT-1988-F
Floor Crane
Mounting Stand
Plastic Scraper
Flat-Bladed Screwdriver
Vise
Vise Jaw Protectors

Materials

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.

NOTICE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

LHD AWD/LHD RWD

1. Inspect the turbocharger or engine air intake system components and clean, if necessary.
   

1. NOTICE: If the engine block skirt stiffener is not installed, aligned and the bolts tightened to minimum specification within 10 minutes, the sealant must be removed and the sealing area cleaned.

   Apply a 3.5 mm (0.14 in) bead of Motorcraft® High Performance Engine RTV Silicone to the chamfer of the engine block skirt stiffener.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. 1. Position the oil seal.
      
   2. Install the engine block skirt stiffener.
      

1. 1. Install the bolts finger tight.
      
   2. Tighten the 2 bolts.
      Torque:
        Stage 1:  35 lb.in (4 Nm)
        Stage 2:  Loosen: 360°

1. 1. Using a straight edge, align the rear face of the engine block skirt stiffener to the rear face of the engine block, flush or up to 0.250 mm (0.01 in) underflush.
      
   2. Using a straight edge, align the machined boss on the left side of the engine block skirt stiffener to the machined boss on the left side of the engine block flush or within 0.280 mm (0.011 in) of flush.
      

1. NOTICE: If the engine block skirt stiffener bolts minimal torque is not completed within 10 minutes of sealant application, or if final torque is not met within 60 minutes of sealant application the parts must be removed and the sealant must be removed and the sealing area cleaned.

   Tighten the engine block skirt stiffener bolts.
   Torque:
     Stage 1:  35 lb.in (4 Nm)
     Stage 2:  18 lb.ft (24 Nm)

1. Install the oil pump drive belt onto the crankshaft sprocket.
   

1. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
   

1. NOTE: Make sure the oil pump drive belt teeth are engaged in the crankshaft sprocket prior to installing the oil pump.

   1. Install the oil pump sprocket into the oil pump drive belt.
      
   2. Raise the rear of the oil pump assembly into the installed position.
      
   3. Install the oil pump bolts.
      Torque:
        Stage 1:  89 lb.in (10 Nm)
        Stage 2:  45°

1. 1. Install new O-ring seals.
      
   2. Lubricate the O-ring seals with clean engine oil.
      

1. • Install the oil return tube and the bolts.
     Torque: 89 lb.in (10 Nm)
   • Install the oil control solenoid and the bolt.
     Torque: 89 lb.in (10 Nm)

1. Install the splash shield and the bolts.
   Torque: 89 lb.in (10 Nm)

1. Install the timing chain sprocket.
   

1. NOTICE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the RH side the triangle marks are used.

   1. Install the RH timing chain with the single colored links aligned with the triangle timing marks on the VCT units.
      
   2. Install the double colored links so they straddle the timing mark on the crankshaft sprocket.
      

1. Install the RH timing chain guide and bolts.
   Torque: 89 lb.in (10 Nm)

1. Install the RH timing chain tensioner arm.
   

1. Slide the tensioner cylinder out of the RH timing chain tensioner housing.
   

1. NOTICE: Use vise jaw protectors or cover the jaws of the vise with clean shop towels to prevent damage to the surface of the tensioner ratchet mechanism.

   Mount the flat machined surfaces on the end of the tensioner cylinder into a vise.
   
   1. Using a flat-bladed screwdriver apply light downward pressure on the end of the tensioner ratchet mechanism.
      Use the General Equipment: Vise
      Use the General Equipment: Vise Jaw Protectors
      Use the General Equipment: Flat-Bladed Screwdriver
   2. Rotate the screwdriver clockwise approximately one turn.
      
   3. An audible click will be heard when the tensioner ratchet mechanism locks into place.
      

1. Slide the tensioner cylinder into the tensioner housing until it contacts the bottom of the bore. The shoulder of the tensioner cylinder will be flush with the top of the housing.
   

1. 1. Firmly press the tensioner cylinder into the tensioner housing until the shoulder of the tensioner cylinder is approximately 3 mm (0.125 in) below the top of the housing.
      
   2. Install a retaining pin into the hole in the housing to lock the tensioner cylinder in the retracted position.
      

1. 1. Position the RH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.
      
   2. Install the bolts.
      Torque: 89 lb.in (10 Nm)
   3. Remove the pin to allow the tensioner cylinder to extend and press against the timing chain tensioner arm.
      

1. Install new engine front cover gaskets.
   

1. 1. Lubricate a new oil gallery seal (6G068) with clean engine oil.
      
   2. Install the new oil gallery seal (6G068).
      

1. NOTICE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

   NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

   Apply 9 mm (0.35 in) beads of Motorcraft® High Performance Engine RTV Silicone 10 mm (0.40 in) in length to the cylinder block skirt-to-cylinder block joints and the cylinder head-to-cylinder block joints as indicated.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. NOTICE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

   NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

   1. Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces of the inner bolt bosses.
      Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
   2. Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the chamfer of the engine front cover sealing surfaces.
      Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. Install the engine front cover and the fasteners.
   Torque:
     Stage 1:  Tighten bolts 1 through 11 to:   18 lb.ft (24 Nm)
     Stage 2:  Tighten bolts 12 through 13 to:   35 lb.ft (48 Nm)
     Stage 3:  Tighten bolts 14 through 20 to:   18 lb.ft (24 Nm)

1. Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
   Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
   Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

1. NOTICE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

   NOTE: The oil pan must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

   1. Install a new gasket.
      
   2. Apply 18 mm (0.7 in) drops of sealant.
      Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. Tighten the bolts in 2 stages.
   Torque:
     Stage 1:  89 lb.in (10 Nm)
     Stage 2:  45°

1. Lubricate the engine front cover bore with clean engine oil.
   

1. Using the special tools, install the new crankshaft front oil seal.
   Use Special Service Tool: 303-335 (T88T-6701-A)  Installer, Front Cover Oil Seal. , 303-1531  Installer, Front Crank Seal and Damper.

1. Lubricate the crankshaft front seal inner lip with clean engine oil.
   

1. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
   

1. Using the special tools, install the crankshaft pulley.
   Use Special Service Tool: 303-335 (T88T-6701-A)  Installer, Front Cover Oil Seal. , 303-1531  Installer, Front Crank Seal and Damper.

1. NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).

   Using a universal pulley holder, install and tighten a new crankshaft pulley bolt.
   Torque:
     Stage 1:  166 lb.ft (225 Nm)
     Stage 2:  Loosen:   360°
     Stage 3:  26 lb.ft (35 Nm)
     Stage 4:  270°

1. NOTE: Installation of new seals is only required if damaged seals were removed.

   Using the special tools, install new spark plug tube seals.
   Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 303-1247  VCT Spark Plug Tube Seal Remover and Installer.

1. Install new gaskets.
   

1. 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. Use a plastic scraping tool to remove all traces of old sealant.

   Clean the valve cover mating surface of the cylinder head and engine front cover.
   Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
   Use the General Equipment: Plastic Scraper
   Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
   Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

1. NOTICE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

   Apply an 8 mm (0.31 in) diameter drop of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. Install the valve cover and tighten the bolts in sequence.
   Torque: 89 lb.in (10 Nm)

1. NOTE: Installation of new seals is only required if damaged seals were removed.

   Using the special tools, install new spark plug tube seals.
   Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 303-1247  VCT Spark Plug Tube Seal Remover and Installer.

1. Install new gaskets
   

1. 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. Use a plastic scraping tool to remove all traces of old sealant.

   Clean the valve cover mating surface of the cylinder head and engine front cover.
   Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
   Use the General Equipment: Plastic Scraper
   Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
   Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

1. NOTICE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

   Apply an 8 mm (0.31 in) diameter drop of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. Install the valve cover and tighten the bolts in sequence.
   Torque: 89 lb.in (10 Nm)

1. Install the bracket and the nuts.
   Torque: 53 lb.in (6 Nm)

1. Inspect and replace any ignition coil-on-plugs that have rubber boots with cracks, rips or tears.
   

1. Install the RH ignition coil-on-plugs and stud bolts.
   Torque: 53 lb.in (6 Nm)

1. Install the LH ignition coil-on-plugs and stud bolts.
   Torque: 53 lb.in (6 Nm)

1. • Lubricate the inside and the outside diameter of the grommet with clean engine coolant.
     
   • Install the grommet so it is flush with the rear of the coolant pump housing.
     

1. Install a new coolant pump gasket.
   

1. NOTE: Verify the front cover dowel pins are aligned to the coolant pump and that the coolant pump is fully seated prior to installing the fasteners.

   • Install the coolant pump and the fasteners.
     Torque:
        Fasteners 1-6:  
       Stage 1:  89 lb.in (10 Nm)
       Stage 2:  45°
   • Torque:
        Fastener 7:   18 lb.ft (24 Nm)
   • Torque:
        Fasteners 8:  
       Stage 1:  89 lb.in (10 Nm)
       Stage 2:  45°

1. 1. Install the coolant pump pulley and the bolts.
      Torque: 18 lb.ft (24 Nm)
   2. Install the idler pulley and the bolt.
      Torque: 35 lb.ft (48 Nm)
   3. Install the idler pulley and the bolt.
      Torque: 18 lb.ft (24 Nm)

1. Install a new oil cooler gasket.
   

1. Install the oil cooler and the fasteners.
   Torque: 89 lb.in (10 Nm)

1. Install a new TC oil return tube-to-engine block gasket.
   

1. Install a new TC oil return tube O-ring seal and lubricate with clean engine oil.
   

1. Install the TC oil return tube and the fasteners.
   Torque: 89 lb.in (10 Nm)

1. If removed, install and tighten the high-pressure fuel pump mounting studs.
   Torque: 106 lb.in (12 Nm)

1. NOTICE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.

   NOTICE: The drive lobe for the high-pressure fuel pump must be at BDC (bottom dead center) for the high-pressure fuel pump installation.

   Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC (bottom dead center).
   

1. Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and the roller tappet.
   

1. Install the high-pressure fuel pump roller tappet.
   

1. NOTE: Apply clean engine oil to the high-pressure fuel pump O-ring seals.

   Install a new high-pressure fuel pump O-ring seal and lubricate with clean engine oil.
   

1. Install the high-pressure fuel pump, then install the mounting nuts finger tight. Alternately tighten each high-pressure fuel pump nut one complete revolution until seated. Tighten the fuel high-pressure fuel pump nuts in the following 2 stages.
   Torque:
     Stage 1:  177 lb.in (20 Nm)
     Stage 2:  45°

1. NOTICE: In stage 4, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 37 lb ft (50 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.

   NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas.

   NOTE: Make sure that a new high-pressure fuel tube is installed.

   Install the high-pressure fuel tube and bracket nuts, tighten the high-pressure fuel tube flare nuts and bracket nuts finger tight.
   Torque:
     Stage 1:  Tighten the high-pressure fuel tube bracket nuts to :   89 lb.in (10 Nm)
     Stage 2:  Tighten the high-pressure fuel tube flare nuts to :   62 lb.in (7 Nm)
     Stage 3:  Tighten the high-pressure fuel tube flare nuts to :   89 lb.in (10 Nm)
     Stage 4:  Tighten the high-pressure fuel tube flare nuts an additional :   25°

1. • Install the gaskets.
     
   • Install the insulator.
     

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

   Install the intake manifold and tighten the bolts.
   Torque: 89 lb.in (10 Nm)

1. Install the coolant pipe and the bolts.
   Torque: 97 lb.in (11 Nm)

1. • Install the vacuum harness onto the engine.
     
   • Attach the vacuum harness retainers.
     
   • Install the bolts.
     Torque: 62 lb.in (7 Nm)

1. • Connect the vacuum harness quick release coupling.
     Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 3.0L EcoBoost, General Procedures).
     
   • Attach the vacuum harness retainer.
     
   • Install the vacuum hose and clamp.
     

1. • Install the wiring harness onto the engine.
     
   • Connect the wiring harness electrical connectors.
     
   • Attach the wiring harness retainers.
     

1. • Attach the wiring harness retainers.
     
   • Connect the wiring harness electrical connectors.
     

1. • Attach the wiring harness retainer.
     
   • Install the ground wire and stud bolt to the rear of the RH cylinder head.
     Torque: 89 lb.in (10 Nm)

1. • Attach the wiring harness retainers.
     
   • Connect the wiring harness electrical connectors.
     

1. • Attach the wiring harness retainers.
     
   • Connect the wiring harness electrical connectors.
     

1. • Connect the CHT electrical connector.
     
   • Slide the wiring harness insulator down.
     
   • Install the ground wire and the stud bolt.
     Torque: 89 lb.in (10 Nm)

1. Install the crankcase vent tube and connect the quick release couplings.
   Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 3.0L EcoBoost, General Procedures).
   

1. • Install the CAC inlet pipe and tighten the clamp.
     Torque: 42 lb.in (4.8 Nm)
   • Install the bolt.
     Torque: 93 lb.in (10.5 Nm)
   • Attach the wiring harness retainer.
     

1. Install the air cleaner outlet pipe and the bolts.
   Torque: 93 lb.in (10.5 Nm)

1. Install the A/C compressor and the bolts.
   Torque: 18 lb.ft (25 Nm)

1. • Install the EVAP tube and connect the quick release coupling.
     Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 3.0L EcoBoost, General Procedures).
     
   • Install the fuel tube assembly and connect the quick release coupling.
     Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 3.0L EcoBoost, General Procedures).
     
   • Attach the fuel tube retainer.
     

1. Install the oil level indicator.
   

LHD AWD

1. Install a new front axle assembly seal and lubricate with clean engine oil.
   

1. 1. Clean the front axle assembly-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
      
   2. Install the front axle assembly and the bolts.
      Torque:
        Stage 1:  66 lb.ft (90 Nm)
        Stage 2:  90°

1. Install a new axle connector seal and lubricate with clean engine oil.
   

1. Install the front axle disconnect actuator and the bolts.
   Torque: 26 lb.ft (35 Nm)

LHD RWD

1. Install the engine mount spacer and the bolt.
   Torque:
     Stage 1:  66 lb.ft (90 Nm)
     Stage 2:  90°

LHD AWD/LHD RWD

1. NOTE: AWD shown, RWD similar.

   Clean the engine mount mating surfaces of any dirt or foreign material prior to installation.
   

1. NOTE: AWD shown, RWD similar.

   Position the RH engine mount and install the new studs.
   Torque: 35 lb.ft (48 Nm)

1. NOTE: AWD shown, RWD similar.

   Install the new bolts and nuts finger-tight and then tighten in sequence.
   Torque:
     Stage 1:  66 lb.ft (90 Nm)
     Stage 2:  90°

1. Clean the engine mount mating surfaces of any dirt or foreign material prior to installation.
   

1. Install the LH engine mount, the new bolts finger-tight and then tighten in sequence.
   Torque: 46 lb.ft (63 Nm)

1. Using a floor crane, remove the engine from the mounting stand.
   Install Special Service Tool: 303-1634  Lift Eyes (2). , 303-1246  Engine Spreader Bar.
   Use the General Equipment: Floor Crane
   Use the General Equipment: Mounting Stand

1. Lubricate the crankshaft rear seal lips with clean engine oil.
   

1. NOTE: The crankshaft rear seal and retainer plate must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

   1. Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the crankshaft rear seal and retainer plate.
      Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
   2. Overlap the beginning and ending of the sealant bead 15 mm (0.59 in).
      Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
   3. Apply 9 mm (0.35 in) beads of Motorcraft® High Performance Engine RTV Silicone that are 10 mm (0.40 in) in length as indicated in the graphic.
      Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. NOTICE: The special tool must be inserted into the rear of the crankshaft seal to prevent the seal lip from rolling backwards.

   1. Insert the magnetic base of the special tool into the rear opening of the crankshaft seal.
      Install Special Service Tool: 303-1250  Seal Installer, Rear Main.
   2. The magnetic base of the special tool should protrude slightly from the front of the seal plate
      

1. • Position the special tool and seal plate onto the end of the crankshaft.
     Use Special Service Tool: 303-1250  Seal Installer, Rear Main.
   • Slide the new crankshaft rear seal and retainer plate onto the crankshaft and into the installed position.
     

1. Install the crankshaft rear seal retainer plate bolts.
   Remove Special Service Tool: 303-1250  Seal Installer, Rear Main.
   Torque: 89 lb.in (10 Nm)

1. 1. Install the CKP sensor and the stud bolt.
      Torque: 89 lb.in (10 Nm)
   2. Connect the CKP sensor electrical connector.
      

1. Install the heat shield and the nut.
   Torque: 89 lb.in (10 Nm)

1. Install the crankshaft sensor ring.
   

1. 1. Position the flexplate on the crankshaft.
      
   2. Install the bolts then rundown the bolts one turn at a time in sequence shown until the flexplate is snug against the rear face of the crankshaft.
      
   3. Final tighten the bolts in sequence shown.
      Torque: 59 lb.ft (80 Nm)

1. Install the engine into the vehicle.
   Refer to: Engine (303-01A Engine - 3.0L EcoBoost, Installation).