SECTION 303-01A:

Engine — 4.2L

SPECIFICATIONS
DESCRIPTION AND OPERATION
Engine
DIAGNOSIS AND TESTING
Engine
IN-VEHICLE REPAIR
Upper Intake Manifold
Lower Intake Manifold
Valve Cover — LH
Valve Cover — RH
Lower End Components — Exploded View
Crankshaft Pulley
Crankshaft Front Seal
Engine Front Cover
Valve Train Components — Exploded View
Push Rod
Rocker Arm
Valve Springs
Valve Seals
Valve Tappet
Timing Drive Components
Camshaft
Engine Dynamic Balance Shaft
Exhaust Manifold — LH
Exhaust Manifold — RH
Cylinder Head
Oil Level Indicator and Tube
Engine Lubrication Components — Exploded View
Oil Pan
Oil Pump Screen and Pickup Tube
Oil Pump
Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View
Flexplate
Flywheel
Crankshaft Rear Seal
Engine Support Insulators
REMOVAL
Engine
DISASSEMBLY
Engine
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head
Piston
ASSEMBLY
Engine
INSTALLATION
Engine
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
SPECIFICATIONS Procedure revision date: 03/03/2008

Material
Item Specification Fill
Capacity
Motorcraft Metal Surface Prep — —
ZC-31-A
Motorcraft Premium Gold Engine WSS- —
Coolant with Bittering Agent M97B51-A1
(bittered in US only)
VC-7-B (US); CVC-7-A (Canada);
or equivalent (yellow color)
Motorcraft SAE 5W-20 Premium WSS- 5.68L (6
Synthetic Blend Motor Oil M2C930-A qt)
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Brake Caliper Grease and ESE-M1C171- —
Dielectric Compound A
XG-3-A
Silicone Gasket and Sealant WSE- —
TA-30 M4G323-A4
Silicone Gasket Remover — —
ZC-30
Thread Sealant with PTFE WSK- —
TA-24 M2G350-A2
Threadlock 262 WSK- —
TA-26 M2G351-A6

General Specifications

Item Specification
Engine
Displacement 4.2L
Number of cylinders 6
Bore 96.8325 mm (3.81 in)
Stroke 95.0 mm (3.74 in)
Firing order 1-4-2-5-3-6
Oil pressure (HOT 2,500 rpm) 275.8-861.9 kPa

(40-125 psi)
Compression ratio —
Engine weight (without flexplate or flywheel or 176 kg (388 lb)
accessory drive components)
Cylinder Head and Valve Train
Cylinder head gasket surface flatness 0.18 mm (0.007 in)
Cylinder head gasket surface finish a
—
Combustion chamber volume 61.5-64.5 cc

(3.75-3.94 cu in)
Valve arrangement (front to rear) (LH cylinder head) E-I-E-I-E-I
Valve arrangement (front to rear) (RH cylinder head) I-E-I-E-I-E
Valve guide bore diameter 7.015-7.044 mm (0.276-0.277 in)
Valve stem diameter — intake (standard) 6.955-6.988 mm (0.2738-0.2751 in)
Valve stem diameter — exhaust 6.929-6.962 mm (0.2728-0.2741 in)
Valve stem diameter — oversize (intake) 9.075-9.055 mm (0.3573-0.3565 in)
Valve stem diameter — oversize (exhaust) 9.063-9.043 mm (0.3568-0.3560 in)
Valve stem diameter — oversize (intake) 9.456-9.436 mm (0.3723-0.3715 in)
Valve stem diameter — oversize (exhaust) 9.444-9.424 mm (0.3718-0.3710 in)
Valve stem-to-guide clearance — intake 0.020-0.069 mm (0.0008-0.0027 in)
Valve stem-to-guide clearance — exhaust 0.038-0.083 mm (0.0015-0.0033 in)
Valve head diameter — intake 47.27 mm (1.86 in)
Valve head diameter — exhaust 37.1 mm (1.46 in)
Valve face runout 0.05 mm (0.002 in)
Valve face angle 45.675 degrees
Valve seat width 1.5-2.0 mm (0.06-0.08 in)
Valve seat runout (TIR) 0.076 mm (0.003 in)
Valve seat angle 44.75 degrees
Valve spring free length —
Valve spring squareness —
Valve spring compression pressure — valve open 1000 N (225 lbs) @
(without damper)
29.2 mm (1.15 in)
Valve spring compression pressure — valve closed 350 N (79 lbs) @
(without damper)
40.7 mm (1.61 in)
Valve spring installed height 40.7 mm (1.61 in)
Valve spring installed pressure —
Rocker arm ratio 1.73 : 1
Hydraulic Lash Adjuster
Diameter (standard) 22.195-22.212 mm (0.8738-0.8745 in)
Clearance to bore 0.018-0.068 mm (0.0007-0.0027 in)
Service limit 0.127 mm (0.005 in)
Hydraulic leakdown rate b
—
Collapsed lash adjuster gap — intake 2.25-4.79 mm (0.089-0.189 in)
Collapsed lash adjuster gap — exhaust 2.25-4.79 mm (0.089-0.189 in)
Camshaft
Theoretical valve lift @ 0 lash — intake 11.30 mm (0.45 in)
Theoretical valve lift @ 0 lash — exhaust 11.47 mm (0.45 in)
Lobe lift — intake 6.22 mm (0.24 in)
Lobe lift — exhaust 6.57 mm (0.26 in)
Allowable lobe lift loss 0.127 mm (0.005 in)
Journal diameter 52.082-52.108 mm (2.0505-2.0515 in)
Camshaft journal bore inside diameter — intake 47.097 mm (1.8542 in) max, 47.072 mm

(1.8532 in) min

Camshaft journal bore inside diameter — exhaust 39.739 mm (1.5645 in) max, 39.714 mm

(1.5635 in) min

Camshaft journal-to-bearing clearance 0.025-0.076 mm (0.001-0.003 in)
Runout 0.05 mm (0.002 in) runout of No. 2 or No. 3
relative to No. 1 and No. 4
End play 0.025-0.150 mm (0.001-0.006 in)
Cylinder Block
Cylinder bore diameter 96.813 mm (3.81 in)
Cylinder bore maximum taper 0.050 mm (0.002 in)
Cylinder bore maximum out-of-round — limit 0.025 mm (0.001 in)
Cylinder bore maximum out-of-round — service limit 0.050 mm (0.002 in)
Main bearing bore inside diameter 68.905-68.885 mm (2.713-2.712 in)
Camshaft bearing bore inside diameter — No. 1 55.689-55.664 mm (2.192-2.191 in)
Camshaft bearing bore inside diameter — No. 2 and 55.308-55.283 mm (2.177-2.176 in)
No. 3
Camshaft bearing bore inside diameter — No. 4 55.684-55.664 mm (2.192-2.191 in)
Head gasket surface flatness 0.08 mm (0.003 in) in 152.0 mm (6.00 in)
Head gasket surface finish (RMS) 2.0 @ 0.85.5 @ 2.5
Crankshaft
Main bearing journal diameter — 1, 2, 3 63.983-64.003 mm (2.5190-2.5198 in)
Main bearing journal maximum taper 0.008 mm (0.0003 in) per 25 mm (1 in)
Main bearing journal maximum out-of-round 0.008 mm (0.0003 in) max in 45 degrees, 0.015
 mm (0.0006 in) total
Main bearing journal-to-cylinder block clearance — 0.025-0.035 mm (0.001-0.0014 in)
desired
Main bearing journal-to-cylinder block clearance — 0.013-0.058 mm (0.0005-0.0023 in)
allowable
Connecting rod journal diameter —
Connecting rod journal maximum taper —
Connecting rod journal maximum out-of-round —
Crankshaft maximum end play 0.10-0.20 mm (0.004-0.008 in)
Thrust bearing journal diameter 58.682-58.702 mm (2.3103-2.3111 in)
Thrust bearing journal maximum out-of-round 0.008 mm (0.0003 in) max in 45 degrees, 0.015
mm (0.0006 in) total
Thrust bearing journal maximum taper — limit 0.008 mm per 25 mm (0.0003 in per inch)
Thrust bearing journal maximum taper — service limit 0.3 microns

(11.8 micro in)

Thrust bearing journal length 29.725-29.775 mm (1.703-1.722 in)
Piston and Connecting Rod
Piston diameter — coded red 96.795-96.782 mm (3.8108-3.8103 in)
Piston diameter — coded blue 96.808-96.795 mm (3.8113-3.8108 in)
Piston diameter — coded yellow 96.821-96.808 mm (3.8119-3.8113 in)
Piston-to-cylinder bore clearance (uncoated 0.018-0.044 mm (0.0007-0.0017 in)
clearance)
Piston ring end gap — compression (top, in gauge) 0.17-0.33 mm (0.0067-0.0130 in)
Piston ring end gap — compression (bottom, in 0.3-0.55 mm (0.0118-0.0217 in)
gauge)
Piston ring end gap — oil ring (steel rail, in gauge) 0.15-0.65 mm (0.006-0.026 in)
Piston ring groove width — compression (top and 1.54-1.52 mm (0.0606-0.0598 in)
bottom)
Piston ring groove width — oil 3.05-3.03 mm (0.1201-0.1193 in)
Piston ring width — compression (top and bottom) 1.460-1.490 mm (0.0575-0.0587 in)
Piston ring width — oil ring Side seal, snug fit
Piston ring-to-groove clearance — 1st ring 0.030-0.080 mm (0.0012-0.0032 in)
Piston ring-to-groove clearance — 2nd ring 0.030-0.080 mm (0.0012-0.0032 in)
Piston pin bore diameter 23.014-23.018 mm (0.9061-0.9062 in)
Piston pin diameter 23.000-23.003 mm (0.9055-0.9056 in)
Piston pin length 63.55-63.05 mm (2.5020-2.4823 in)
Piston pin-to-piston fit 0.011-0.018 mm (0.0004-0.0007 in)
Piston-to-connecting rod clearance Press fit 8 kilonewtons (1,800 lb)
Connecting rod-to-pin clearance —
Connecting rod pin bore diameter 22.94-22.98 mm (0.9032-0.9047 in)
Connecting rod length (center-to-center) 154.66-154.74 mm (6.0890-6.0921 in)
Connecting rod maximum allowable bend 0.04 per 25 mm

(0.0016 in per inch)

Connecting rod maximum allowable twist 0.059 per 25 mm

(0.002 in per inch)

Connecting rod bearing bore diameter 61.635-61.655 mm (2.4266-2.4274 in)
Connecting rod bearing-to-crankshaft clearance — 0.025-0.035 mm (0.001-0.0014 in)
desired
Connecting rod bearing-to-crankshaft clearance — 0.022-0.069 mm (0.0009-0.0027 in)
allowable
Connecting rod side clearance (assembled to crank) 0.11-0.49 mm (0.0043-0.0193 in)
— standard
Connecting rod side clearance (assembled to crank) 0.36 mm (0.014 in) max.
— service limit
Balance Shaft
Journal diameter 52.108-52.082 mm (2.0515-2.0505 in)
Bore inside diameter 55.689-55.664 mm (2.192-2.191 in)
Maximum runout 0.025 mm (0.001 in)
End play 0.075-0.200 mm (0.003-0.008 in)
a
Head gasket surface — WT = 12/2.5. Head gasket surface finish — RZU-13.5 micron. Filter cut off at
0.08 min TPI @ 3.5 microns below the peak 63% min. Cut off at 0.08 mm (0.031496 in), O Ref = 2V.
b
20-200 seconds to leakdown 3.18 mm (0.125 in) with 225 N (50.6 lb) load and tappet filled with leak-
down fluid.

Torque Specifications

Description Nm lb-ft lb-in

A/C compressor and power steering pump bracket bolt 48 35 —
A/C compressor and power steering pump bracket brace bolts 48 35 —
A/C compressor and power steering pump bracket brace nuts 25 18 —
Accessory drive belt idler pulley bolt 55 41 —
Accessory drive belt tensioner bolt 55 41 —
Camshaft position sensor bolts 6 — 53
Camshaft synchronizer drive gear bolt 45 33 —
Camshaft synchronizer retaining bolt 25 18 —
Camshaft thrust plate bolts 11 8 —
Clutch pressure plate bolts 25 18 —
Connecting rod cap bolts a — — —
Coolant pump pulley bolts 25 18 —
Cooling fan shroud bolts 10 — 89
Crankshaft pulley bolt 160 118 —
Crossmember bolts 90 66 —
Cylinder block drain plug 32 24 —
Dual converter Y-pipe-to-exhaust manifold nuts 40 30 —
Engine dynamic balance shaft thrust plate bolts 11 8 —
Engine front cover bolts, stud bolts and nuts a
— — —
Engine lifting eye nuts 25 18 —
Engine support insulator bolts 115 85 —
Engine support insulator bracket bolts 48 35 —
Engine support insulator nuts 250 184 —
Engine support insulator through bolt 350 258 —
Exhaust manifold nuts a
— — —
Exhaust manifold studs 12 9 —
Exhaust manifold-to-exhaust gas recirculation (EGR) system module tube fittings 40 30 —
Flexplate bolts 80 59 —
Flywheel bolts 80 59 —
Front crossmember bolts 115 85 —
Fuel rail bolts 10 — 89
Generator B+ terminal nut 8 — 71
Generator mounting bracket lower bolts 48 35 —
Generator mounting bracket upper bolt 25 18 —
Ground wire bolt 10 — 89
Heater hose bracket bolt 5 — 44
Heater outlet tube bolt 10 — 89
Hood bolts 30 22 —
Ignition coil bolts 7 — 62
Lower intake manifold bolts a
— — —
Main bearing cap stud bolts a
— — —
Oil drain plug 26 19 —
Oil filter 16 12 —
Oil level indicator and tube bolt 10 — 89
Oil pan baffle nuts 32 24 —
Oil pan bolts a
— — —
Oil pan-to-transmission bolts 34 25 —
Oil pressure sender 27 20 —
Oil pump bolts (large) 28 21 —
Oil pump bolts (small) 10 — 89
Oil pump screen and pickup tube bolts 25 18 —
Oil pump screen and pickup tube nut 32 24 —
Power steering fluid reservoir bolts 10 — 89
Power steering fluid reservoir bracket bolts and stud bolt 20 15 —
Power steering pump bolts 25 18 —
Power steering pressure hose bracket nut 10 — 89
Radio interference capacitor bolt 10 — 89
Rocker arm bolts a
— — —
Spark plugs 15 11 —
Starter wiring harness bracket nut 20 15 —
Tappet guide plate bolts 12 9 —
Timing chain tensioner bolts 11 8 —
Torque converter nuts 36 27 —
Transmission cooler tube bracket nut 20 15 —
Transmission-to-engine bolts 47 35 —
Upper intake manifold bolts a
— — —
Valve cover bolts and stud bolts 10 — 89
a
Refer to the procedure in this section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
DESCRIPTION AND OPERATION Procedure revision date: 07/14/2006

Engine

The 4.2L (256 CID) 6-cylinder engine has the following features:

 A V-block with 6 cylinders and splayed crankpins

 A distributorless ignition system
 A multi-port, sequential fuel injection (SFI) system
 A variable length induction system (intake manifold runner control [IMRC])
 Overhead valves
 Hydraulic valve tappets for automatic lash adjustment
 Connecting rod parting faces that are unique with an interference fit
 An engine dynamic balance shaft

The 4.2L engine is a 2 valve-per-cylinder, push rod engine. The engine uses a distributorless ignition
system. The camshaft is mounted in the cylinder block and acts against push rods to open and close the
valves. The camshaft is driven off the front of the cylinder block by a timing chain. The chain is driven by
a sprocket that is located on the crankshaft. The camshaft also drives an engine dynamic balance shaft,
mounted above the camshaft in the engine block, via gears mounted to the front of both the camshaft and
engine dynamic balance shaft. The piston assembly is an aluminum piston with a cast iron connecting
rod. The oil pump is driven by the camshaft via a gear that also drives the camshaft synchronizer.

Identification

Always refer to these labels when installation of new parts is necessary, or when checking engine
calibrations. The engine parts often differ within a CID family. Verification of the identification codes will
make sure that the correct parts are obtained. These codes contain all the pertinent information relating to
the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of
the codes and their application.

Code Information

The engine code information label, located on the side of the valve cover and the front side of the valve
cover, contains the:

 engine build date.

 engine plant code.
 engine code.

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated
fuel injectors:

 are mounted in the lower intake manifold.

 meter fuel to the air intake stream in accordance with engine demand.
 are positioned so their tips direct fuel just ahead of the engine intake valves
The 4.2L air induction system improves engine performance by using the IMRC assemblies as follows:

 The intake manifold has 2 runners per cylinder, feeding the intake ports in the cylinder heads.
 The IMRC assemblies are located in the lower intake manifold, providing 2 air passages for each
cylinder.
 One air passage is always open and the other passage switches from closed to open by means
of a valve plate.
 The valve plates are opened and closed by the IMRC electric actuator, which is controlled by the
PCM.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake
manifold

Lubrication System

The engine lubrication system operates as follows:

 Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil
pan.
 Oil is pumped through the oil filter on the left front side of the cylinder block.
 Oil enters the main gallery where it is distributed to the crankshaft main journals and to the
cylinder head.
 From the main journals, the oil is routed through cross-drilled passages in the crankshaft to
lubricate the connecting rod bearings. Controlled leakage through the crankshaft main
bearings and connecting rod bearings is slung radially outward to cool and lubricate the
cylinder walls as well as the entire connecting rod, piston and piston ring assembly.

Engine Cylinder Identification

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
DIAGNOSIS AND TESTING Procedure revision date: 07/14/2006

Engine

Refer to Section 303-00 for basic mechanical concerns or refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for driveability concerns.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 12/09/2008

Upper Intake Manifold

Material
Item Specification
Silicone Brake Caliper Grease and ESE-M1C171-
Dielectric Compound A
XG-3-A

Upper Intake Manifold Attachments

Item Part Number Description
1 N807309 Heater hose bracket bolt (2 required)
2 18K422 Heater hose bracket
3 4E499 EGR system module vacuum connector
4 9D477 Exhaust manifold-to-EGR system module tube
5 14A464 EGR system module electrical connector
6 W704840 Vapor hose clamp
7 9D289 Vapor hose
8 14A464 Electronic throttle body (TB) electrical connector
9 12286 Spark plug wires (3 required)
10 12297 Spark plug wire retainer (2 required)
11 13A506 Wiring harness retainer (5 required)
12 W706142 Brake booster vacuum hose clamp
13 2B432 Brake booster vacuum hose

Vacuum, Electrical and PCV Connections

 Part
Item Number Description
1 9E499 Intake manifold vacuum hose connector
2 14A163 Fuel charging wiring harness-to-main engine wiring
harness electrical connector retainer
3 8287 Heated PCV outlet hose clamp
4 8A520 Heated PCV outlet hose
5 8287 Heated PCV inlet hose clamp
6 18465 Heated PCV inlet hose
7 6758 PCV valve hose

Upper Intake Manifold

Item Part Number Description

1 9Y450 Upper intake manifold bolt (8 required)
2 9424 Upper intake manifold
3 9H486 Upper intake manifold gasket (6 required)

Removal

1. Drain the engine cooling system. For additional information, refer to Section 303-03 .

2. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

3. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12 .

4. Remove the 2 bolts and position the heater hoses aside.

5. NOTICE: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
 NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark the spark
plug wires for installation reference.

Disconnect the 3 LH spark plug wires from the ignition coil, disconnect the 2 spark plug wire
retainers from the upper intake manifold and position the LH spark plug wires aside.

6. Disconnect the EGR system module electrical and vacuum connectors.

7. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module.

8. Disconnect the electronic throttle body (TB) electrical connector.

9. Release the clamp and disconnect the fuel vapor tube from the upper intake manifold.

10. Disconnect the 5 wiring harness retainers from the upper intake manifold.

11. Release the clamp and disconnect the brake booster vacuum hose from the upper intake
manifold.

12. Disconnect the vacuum hose connector from the rear of the upper intake manifold.

13. Release the clamps and disconnect the 2 heated PCV coolant hoses from the rear of the
upper intake manifold.

14. Disconnect the PCV valve hose from the rear of the upper intake manifold.

15. Detach the fuel charging wiring harness-to-main engine wiring harness electrical connector
retainer from the rear of the upper intake manifold.

16. Remove the 8 bolts and the upper intake manifold.

Installation

1. Inspect the 6 upper intake manifold gaskets. Install new gaskets, if necessary.

2. 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.

Position the upper intake manifold and install the bolts. Tighten the bolts in the sequence
shown in 2 stages.

 Stage 1: Tighten to 6 Nm (53 lb-in).

 Stage 2: Tighten to 10 Nm (89 lb-in).
3. Attach the fuel charging wiring harness-to-main engine wiring harness electrical connector
retainer to the rear of the upper intake manifold.

4. Connect the PCV valve hose to the rear of the upper intake manifold.

5. Connect the 2 heated PCV coolant hoses to the rear of the upper intake manifold and position
the clamps.

6. Connect the vacuum hose connector to the rear of the upper intake manifold.

7. Connect the brake booster vacuum hose to the upper intake manifold and position the clamp.

8. Connect the 5 wiring harness retainers to the upper intake manifold.

9. Connect the fuel vapor hose to the upper intake manifold and position the clamp.

10. Connect the electronic throttle body (TB) electrical connector.

11. Connect the exhaust manifold-to-EGR system module tube to the EGR system module.
 Tighten to 40 Nm (30 lb-ft).

12. Connect the EGR system module electrical and vacuum connectors.
13. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark
plug wire boots.

NOTE: Spark plug wires must be connected to the correct ignition coil terminals.

Position the spark plug wires, connect the 2 spark plug wire retainers to the upper intake
manifold and connect the 3 spark plug wires to the ignition coil.

14. Position the heater hoses and install the bolt.

 Tighten to 5 Nm (44 lb-in).

15. Install the air cleaner outlet pipe. For additional information, refer to Section 303-12 .

16. Connect the battery ground cable. For additional information, refer to Section 414-01 .

17. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 12/09/2008

Lower Intake Manifold

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Silicone Gasket and Sealant TA- WSE-M4G323-
30 A4
Silicone Gasket Remover ZC-30 —

Fuel Rail and Heater and Radiator Hoses

Part
Item Number Description
1 W708650 Fuel rail bolt (4 required)
2 14A624 Fuel charging wiring harness-to-main engine wiring
 harness electrical connector
3 14489 Intake manifold runner control (IMRC) actuator
electrical connector
4 — Fuel rail, fuel charging wiring harness and vacuum
harness assembly
5 15161 Heater outlet hose clamp
6 18K580 Heater outlet hose
7 15161 Radiator hose clamp
8 8260 Radiator hose
9 8287 Bypass hose clamp
10 8A582 Bypass hose
11 15161 Heater inlet hose clamp
12 18K579 Heater inlet hose

Lower Intake Manifold

Item Part Number Description

1 W701569 Lower intake manifold long bolt (6 required)
2 W711496 Lower intake manifold short bolt (8 required)
3 9J447 Lower intake manifold
4 9441 LH lower intake manifold gasket
5 9439 RH lower intake manifold gasket
6 9A425 Lower intake manifold rear seal
7 9A424 Lower intake manifold front seal

Removal

1. Disconnect the fuel supply spring lock coupling. For additional information, refer to Section
310-00 .

2. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in
this section.

3. Disconnect the fuel charging wiring harness-to-main engine wiring harness and the intake
manifold runner control (IMRC) actuator electrical connectors.

4. Remove the bolts and the fuel rail, the fuel charging wiring harness and the engine vacuum
hose harness as an assembly.

5. Release the clamp and disconnect the heater outlet hose.

6. Release the clamp and disconnect the upper radiator hose.

7. Release the clamp and disconnect the bypass hose.

8. Release the clamp and disconnect the heater inlet hose.

9. Remove the 6 long and 8 short bolts, the lower intake manifold, the lower intake manifold
gaskets and the front and rear seals.

Installation

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.

Using a plastic scraping tool, silicone gasket remover and metal surface prep, clean the gasket
mating surfaces. Follow the directions on the packaging.

2. NOTE: If the lower intake manifold is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover
and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure
can cause future oil leakage.

Install the lower intake manifold front and rear seals.

1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear seal
mounting points as indicated.
 2. Install the lower intake manifold front and rear seals.

3. Install the intake manifold gaskets.

4. 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.
 NOTE: If the lower intake manifold is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover
and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure
can cause future oil leakage.

Position the lower intake manifold.

1. Apply a bead of silicone gasket and sealant to the lower intake manifold gaskets and
front and rear seal junctions in 4 places as shown.

2. Position the lower intake manifold.

5. NOTE: Make sure the bolts are installed in the correct locations. The long bolts are installed in
positions 1, 2, 3, 4, 11 and 12.

Tighten the bolts in the sequence shown in 2 stages.

 Stage 1: Tighten to 5 Nm (44 lb-in).

 Stage 2: Tighten to 10 Nm (89 lb-in).
6. Connect the heater inlet hose and position the clamp.

7. Connect the bypass hose and position the clamp.

8. Connect the upper radiator hose and position the clamp.

9. Connect the heater outlet hose and position the clamp.

10. Position the fuel rail, the fuel charging wiring harness and the engine vacuum hose harness as
an assembly and install the bolts.
 Tighten to 10 Nm (89 lb-in).

11. Connect the IMRC actuator and the fuel charging wiring harness-to-main engine wiring
harness electrical connectors.

12. Connect the fuel supply spring lock coupling. For additional information, refer to Section 310-
00 .

13. Install the upper intake manifold. For additional information, refer to Upper Intake Manifold in
this section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 03/03/2008

Valve Cover — LH

Special Tool(s)
Remover, Spark Plug Wire
303-106 (T74P-6666-A)

Material
Item Specification
Silicone Brake Caliper Grease and ESE-M1C171-
Dielectric Compound A
XG-3-A

Crankcase Breather Hose, Spark Plug Wires and Oil Level Indicator Tube
 Item Part Number Description
1 6C342 Crankcase breather hose
2 12286 Spark plug wire
3 12297 Spark plug wire retainer
4 W708650 Oil level indicator tube bolt
5 6754 Oil level indicator tube

LH Valve Cover
Item Part Number Description
1 N621939 Engine lifting eye nuts (2 required)
2 17A084 Engine lifting eye
3 6C519 Valve cover stud bolt (2 required)
4 6C519 Valve cover bolt (3 required)
5 6A513 LH valve cover
6 6584 LH valve cover gasket

Removal and Installation

1. Disconnect the crankcase breather hose.

2. Remove the bolt and position the oil level indicator and tube assembly aside.

3. Remove the nuts and the engine lifting eye.

 To install, tighten to 25 Nm (18 lb-ft).

4. CAUTION: It is important to twist the spark plug boots while pulling upward to
avoid possible damage to the spark plug wires.

NOTE: Spark plug wires must be connected to the correct spark plug. Mark the spark plug
wires for assembly reference.

Using the special tool, with a twisting motion, disconnect the 3 spark plug wires from the spark
plugs.

 To install, lubricate the inside of the spark plug boots with silicone brake caliper grease
and dielectric compound.

5. Disconnect the 2 spark plug wire retainers and position the spark plug wires aside.

6. Remove the 3 bolts, the 2 stud bolts and the LH valve cover.
 To install, tighten to 10 Nm (89 lb-in).

7. Remove and discard the LH valve cover gasket.

8. To install, reverse the removal procedure.

 Install a new LH valve cover gasket.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 03/03/2008

Valve Cover — RH

PCV Connections, Radio Interference Capacitor and Engine Lifting Eye

Item Part Number Description

1 6758 PCV valve hose
2 14A464 PCV valve electrical connector
3 W708650 Radio interference capacitor bolt
4 18801 Radio interference capacitor
5 N621939 Engine lifting eye nuts (2 required)
6 17A084 Engine lifting eye

RH Valve Cover
Item Part Number Description
1 12297 Spark plug wire retainers (2 required)
2 6C519 Valve cover stud bolt (3 required)
3 6C519 Valve cover bolt (2 required)
4 6583 RH valve cover
5 6584 RH valve cover gasket

Removal and Installation

1. Remove the ignition coil. For additional information, refer to Section 303-07A .

2. Disconnect the PCV valve hose and electrical connector.

 Detach the wiring harness retainer from the valve cover stud bolt.

3. Remove the nuts and the engine lifting eye.

 To install, tighten to 25 Nm (18 lb-ft).

4. Detach the spark plug wire retainers.

5. Remove the bolt and position the radio interference capacitor aside.
 To install, tighten to 10 Nm (89 lb-in).

6. Remove the bolts, the stud bolts and the RH valve cover.
 To install, tighten to 10 Nm (89 lb-in).

7. Remove and discard the RH valve cover gasket.

8. To install, reverse the removal procedure.

 Install a new RH valve cover gasket.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Lower End Components — Exploded View

Item Part Number Description

1 N808089 Crankshaft pulley bolt
2 N801539 Washer
3 6B321 Crankshaft pulley
4 6700 Crankshaft front seal

1. For additional information, refer to the procedures in this section.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Crankshaft Pulley

Special Tool(s)
Installer, Crankshaft
Damper/Crankshaft Front Oil
Seal
303-175 (T82L-6316-A)

Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D)

Remover, Crankshaft Vibration

Damper
303-176 (T82L-6316-B)

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

Material
Item Specification
Silicone Gasket and Sealant TA- WSE-M4G323-
30 A4

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the accessory drive belt. For additional information, refer to Section 303-05 .

3. Remove the fan blade assembly. For additional information, refer to Section 303-03 .
 4. Using the special tool to prevent crankshaft rotation, remove the crankshaft pulley bolt and
washer.

5. Using the special tools, remove the crankshaft pulley.

Installation

1. Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper and use
the special tool to install the crankshaft damper.
2. Using the special tool to prevent crankshaft rotation, install the bolt.
 Tighten to 160 Nm (118 lb-ft).

3. Install the fan blade assembly. For additional information, refer to Section 303-03 .

4. Install the drive belt. For additional information, refer to Section 303-05 .
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Crankshaft Front Seal

Special Tool(s)
Installer, Crankshaft Front Oil
Seal
303-474 (T94P-6701-AH)

Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)

Remover, Oil Seal

303-409 (T92C-6700-CH)

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section.

2. Using the special tool, remove the crankshaft front seal. Discard the crankshaft front seal.
Installation

1. Inspect the crankshaft damper and the engine front cover for damage that may cause the
crankshaft front seal to fail.

2. NOTE: Lubricate the crankshaft front seal with clean engine oil.

Using the special tools, install the crankshaft front seal.

3. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 03/03/2008

Engine Front Cover

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket and Sealant TA-30 WSE-
M4G323-A4
Silicone Gasket Remover —
ZC-30
Thread Sealant with PTFE WSK-
TA-24 M2G350-A2

Accessory Drive Belt Tensioner, Power Steering Pump and Bracket Brace
Item Part Number Description
1 — Accessory drive belt tensioner bolt (part of 6B209)
2 6B209 Accessory drive belt tensioner
3 N808113 Bracket brace bolt
4 19D626 Bracket brace
5 N806176 Power steering pump bolt (4 required)
6 3A674 Power steering pump
Engine Front Cover

Part
Item Number Description
1 14A464 Crankshaft position (CKP) sensor electrical
connector
2 N804601 Oil pan bolts (2 required)
3 W701621 Cap screw
4 N804839 Bolt
5 N805112 Stud bolts
6 6019 Engine front cover
7 6020 Engine front cover gasket
8 N804853 Studs (2 required)
9 N805757 Studs (2 required)

Removal

CAUTION: 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 may cause engine failure.
 1. Remove the coolant pump. For additional information, refer to Section 303-03 .

2. Remove the camshaft synchronizer. For additional information, refer to Section 303-14 .

3. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in
this section.

4. Disconnect the crankshaft position (CKP) sensor electrical connector.

 Detach the wiring harness retainers from the engine front cover stud bolts.

5. Drain the engine oil. Install the drain plug when finished.
 Tighten to 26 Nm (19 lb-ft).

6. Remove the oil filter.

7. Remove the 2 oil pan-to-engine front cover bolts.

8. If equipped, remove the retaining nut and position the transmission coolant tube support
bracket aside.

9. Remove the bolt and the accessory drive belt tensioner.

10. NOTE: Loosen the 2 upper bolts and the lower rear bolt first, then loosen the lower front bolt
while sliding the power steering pump out.

Loosen the 4 power steering pump bolts and slide the power steering pump out approximately
25 mm (1 in).

11. Remove the bolt and the A/C compressor and power steering pump bracket brace.

12. CAUTION: The cap screw is concealed by the oil pump housing. Failure to remove
this retainer will result in damage to the engine front cover.

Remove the bolt and the stud bolts. Slide the engine front cover from the studs. Remove and
discard the gasket.

13. NOTE: There are 2 different studs. Note the locations of the studs for installation reference.

Remove the 4 studs.

Installation

1. CAUTION: In order to prevent foreign material from contaminating the engine

block or the engine front cover, it is necessary to seal the coolant and oil passages of
both components. Failure to follow these directions will result in engine damage.

CAUTION: 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 and inspect the engine block and engine front cover as follows:

 Pack the exposed portion of the oil pan with clean shop towels.
 Plug the oil and coolant passages.
 Clean the gasket surfaces. Use silicone gasket remover and metal surface prep. Follow
the directions on the packaging.
 Using compressed air, remove any remaining foreign material from the engine block and
front cover.
 Remove the shop towels from the oil pan.
 Remove the plugs or seals from the oil and coolant passages.

2. Apply thread sealant to the threads on the studs and the cap screw.

3. Install the engine front cover studs.

 Tighten to 7 Nm (62 lb-in).

4. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed
and the sealing areas cleaned. To clean the sealing area, use silicone gasket remover and
metal surface prep. Follow the directions on the packaging. Failure to follow this procedure
may cause future oil leakage.

Apply silicone gasket and sealant as shown.

5. Install the engine front cover gasket.

6. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed
and the sealing areas cleaned. To clean the sealing area, use silicone gasket remover and
metal surface prep. Follow the directions on the packaging. Failure to follow this procedure
may cause future oil leakage.

Apply silicone gasket and sealant to the oil pan as shown.

7. CAUTION: The coolant pump and gasket must be installed at this time to correctly
tighten all of the engine front cover fasteners in sequence. Failure to follow this
instruction may cause future oil leaks.

Install the engine front cover and coolant pump.

 Position the engine front cover and install the bolt, the stud bolts and the cap screw finger
tight.
 Position a new coolant pump gasket and the coolant pump and install the fasteners finger
tight.
 Tighten the fasteners in the sequence shown.
 Tighten capscrew No. 12 to 10 Nm (89 lb-in).
 Tighten all other fasteners to 28 Nm (21 lb-ft).
8. If equipped, position the transmission cooler tube bracket and install the nut.
 Tighten to 20 Nm (15 lb-ft).

9. Install the accessory drive belt tensioner and the bolt.

 Tighten to 55 Nm (41 lb-ft).

10. Install the 2 oil pan-to-engine front cover bolts.

 Tighten to 10 Nm (89 lb-in).

11. Install a new oil filter.

 Tighten to 16 Nm (12 lb-ft).

12. Connect the CKP sensor electrical connector.

 Attach the wiring harness retainers to the engine front cover stud bolts.

13. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in
this section.

14. Install the camshaft synchronizer. For additional information, refer to Section 303-14 .

15. Position the coolant pump pulley and install the bolts.
 Tighten to 25 Nm (18 lb-ft).
16. Position the A/C compressor and power steering pump pulley bracket brace and install the 2
bolts and 2 nuts.
 Tighten the bolts to 48 Nm (35 lb-ft).
 Tighten the nuts to 25 Nm (18 lb-ft).

17. NOTE: Slide the power steering pump in while tightening the front lower bolt, then tighten the
rear lower and 2 upper bolts.

Tighten the power steering pump bolts.

 Tighten to 25 Nm (18 lb-ft).

18. Install the accessory drive belt. For additional information, refer to Section 303-05 .

19. Install the cooling fan and fan shroud. For additional information, refer to Section 303-03 .

20. Fill the engine with clean engine oil.

21. Fill and bleed the cooling system. For additional information, refer to Section 303-03 .
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Valve Train Components — Exploded View

Item Part Number Description

1 N808305 Rocker arm bolt (12 required)
2 6A528 Rocker arm pivot (12 required)
3 6564 Rocker arm (12 required)
4 6565 Push rod (12 required)
5 — Tappet guide plate bolt (4 required) (part of 6K564)
6 6K564 Tappet guide plate (2 required)
7 6500 Valve tappet (12 required)
8 6518 Valve spring retainer key (24 required)
9 6514 Valve spring retainer (12 required)
10 6513 Valve spring (12 required)
11 6A517 Valve stem seal (12 required)

1. For additional information, refer to the procedures in this section.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Push Rod

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal and Installation

CAUTION: 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 may cause engine damage.

1. Remove the rocker arms. For additional information, refer to Rocker Arm in this section.

2. NOTE: If the push rods are to be reused, they must be installed in their original locations. Mark
the push rods for location.

Remove the push rods.

3. Inspect the push rods. For additional information, refer to Section 303-00 .

4. NOTE: Lubricate the push rods with clean engine oil.

To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Rocker Arm

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

CAUTION: 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 may cause engine damage.

1. Remove the valve cover. For additional information, refer to Valve Cover — LH or Valve Cover
— RH in this section.

2. NOTE: If the rocker arms are to be reused, they must be installed in their original locations.
Mark the rocker arms for location.

Remove the bolts, the rocker arm pivots and the rocker arms.

3. Inspect the rocker arms. For additional information, refer to Section 303-00 .

Installation

1. NOTE: Lubricate the rocker arms and pivots with clean engine oil.

Position the rocker arms and the pivots and install the bolts. Tighten the bolts in 2 stages.

 Stage 1: Tighten to 5 Nm (44 lb-in).

 Stage 2: Tighten to 32 Nm (24 lb-ft).

2. Install the valve cover. For additional information, refer to Valve Cover — LH or Valve Cover —
RH in this section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Valve Springs

Special Tool(s)
Compressor, Valve Spring
303-163 (T81P-6513-A)

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal and Installation

1. Rotate the crankshaft until the piston is at the top of its stroke with both the intake valve and
the exhaust valve closed.

2. Remove the rocker arm. For additional information, refer to Rocker Arm in this section.

3. NOTE: If a valve drops into the cylinder, remove the cylinder head. For additional information,
refer to Cylinder Head in this section.

Hold the valve in the cylinder head.

 Remove the spark plug.

 To install, tighten to 15 Nm (11 lb-ft).
 Apply a minimum of 689 kPa (100 psi) of compressed air to the cylinder.

4. Using the special tool, compress the valve spring.

5. Remove the valve spring retainer keys, the valve spring retainer and the valve spring.

6. Inspect the components. For additional information, refer to Section 303-00 .

7. NOTE: Do not release the compressed air from the cylinder until after the valve spring keys
are installed.

NOTE: Lubricate the components with clean engine oil.

To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Valve Seals

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal and Installation

CAUTION: 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.

1. Remove the valve springs. For additional information, refer to Valve Springs in this section.

2. Remove the valve seals.

3. NOTE: Lubricate the valve seals with clean engine oil.

To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Valve Tappet

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal and Installation

NOTE: If removing more than one valve tappet, mark the components removed for correct location.

1. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.

2. Remove the push rods. For additional information, refer to Push Rod in this section.

3. NOTE: If the tappet guide plates are to be reused, they must be installed in their original
locations. Mark the tappet guide plates for location.

Remove the 4 tappet guide plate bolts and the 2 tappet guide plates.

 To install, tighten to 12 Nm (9 lb-ft).

4. NOTE: If the valve tappets are to be reused, they must be installed in their original locations.
Mark the valve tappets for location.

Remove the valve tappets.

5. Inspect the valve tappets. For additional information, refer to Section 303-00 .

6. NOTE: Lubricate the valve tappets with clean engine oil.

To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Timing Drive Components

Item Part Number Description

1 N808319 Camshaft synchronizer drive gear bolt
2 6255 Camshaft synchronizer drive gear
3 6268 Timing chain
4 6306 Crankshaft timing gear
5 6256 Camshaft timing gear
6 N605890 Timing chain tensioner bolt (2 required)
7 6K254 Timing chain tensioner

Removal

1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this
section.

2. Remove the camshaft synchronizer drive gear.

1. Remove the bolt.

2. Remove the camshaft synchronizer drive gear.

3. Rotate the crankshaft until the timing marks and keyways align.

4. Compress and install a retaining pin to hold the timing chain tensioner.

5. Remove the camshaft sprocket, the crankshaft sprocket and the timing chain as an assembly.
 6. Remove the bolts and the timing chain tensioner.

Installation

1. Install the timing chain tensioner and the bolts.

 Tighten to 12 Nm (9 lb-ft).

2. If necessary, retract the tensioner pad retracting mechanism and insert a retaining pin.
3. Rotate the crankshaft so the No. 1 piston is at top dead center (TDC) and the key is at the 12
o'clock position.

4. Turn the camshaft sprocket so that the timing mark is at the 12 o'clock position and is lined up
with the timing mark on the balance shaft at the 6 o'clock position.

5. Install the timing chain, the camshaft sprocket and the crankshaft sprocket.
6. Make sure that the timing marks and the keyways are aligned.

7. Remove the retaining pin.

8. Install the camshaft synchronizer drive gear and the bolt.

 Tighten to 45 Nm (33 lb-ft).
9. Install the engine front cover. For additional information, refer to Engine Front Cover in this
section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Camshaft

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Item Part Number Description

1 6A303 Engine dynamic balance shaft drive gear
2 N804621 Camshaft thrust plate bolt (2 required)
3 6269 Camshaft thrust plate
4 6265 Camshaft spacer
5 N705934 Camshaft Woodruff key
6 6250 Camshaft

Removal

1. Remove the valve tappets. For additional information, refer to Valve Tappet in this section.

2. NOTE: It is not necessary to remove the timing chain tensioner.

 Remove the timing drive components. For additional information, refer to Timing Drive
Components in this section.

3. Remove the engine dynamic balance shaft drive gear.

4. Remove the camshaft Woodruff key.

5. Remove the bolts and the camshaft thrust plate.

6. Remove the camshaft spacer.

7. Remove the camshaft.

Installation

1. Lubricate the camshaft with clean engine oil and install it in the engine block.

2. Install the camshaft spacer.

3. Install the camshaft thrust plate and the bolts.

 Tighten to 11 Nm (8 lb-ft).

4. Install the camshaft Woodruff key.

5. Make sure the engine dynamic balance shaft Woodruff key is at the 12 o'clock position and the
camshaft Woodruff key is at the 6 o'clock position.

6. Install the engine dynamic balance shaft drive gear on the camshaft. Make sure the timing
marks on the drive gear and driven gear are lined up.

7. Install the timing drive components. For additional information, refer to Timing Drive
Components in this section.

8. Install the valve tappets. For additional information, refer to Valve Tappet in this section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 03/03/2008

Engine Dynamic Balance Shaft

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Part
Item Number Description
1 6A303 Engine dynamic shaft drive gear
2 N804621 Engine dynamic balance shaft thrust plate bolt (2
required)
3 6A311 Engine dynamic balance shaft

Removal

1. NOTE: It is not necessary to remove the timing chain tensioner.

Remove the timing drive components. For additional information, refer to Timing Drive
Components in this section.
 2. Remove the engine dynamic balance shaft drive gear.

3. Remove the bolts and the engine dynamic balance shaft.

Installation

1. Lubricate the engine dynamic balance shaft with clean engine oil and install it in the engine
block.

2. Install the bolts.

 Tighten to 11 Nm (8 lb-ft).

3. Make sure the engine dynamic balance shaft Woodruff key is at the 12 o'clock position and the
camshaft Woodruff key is at the 6 o'clock position.

4. Install the engine dynamic balance shaft drive gear on the camshaft. Make sure the timing
marks on the drive gear and driven gear are lined up.

5. Install the timing drive components. For additional information, refer to Timing Drive
Components in this section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Exhaust Manifold — LH

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
 Part
Item Number Description
1 W708650 Oil level indicator tube bolt
2 6754 Oil level indicator tube
3 14A464 LH heated oxygen sensor (HO2S) electrical
connector
4 N800419 Dual converter Y-pipe nut (2 required)
5 5G218 Dual converter Y-pipe
6 N621939 Engine lifting eye nut (2 required)
7 17A084 Engine lifting eye
8 W701706 LH exhaust manifold nut (6 required)
9 9431 LH exhaust manifold
10 9448 LH exhaust manifold gasket
11 W701768 LH exhaust manifold studs (2 required)
12 N811313 LH exhaust manifold stud (4 required)

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the bolt and the oil level indicator and tube.

3. Disconnect the LH heated oxygen sensor (HO2S) electrical connector.

4. Remove the 2 nuts and detach the dual converter Y-pipe.

5. Remove the 2 nuts and the engine lifting eye.

6. Remove the 6 nuts, the LH exhaust manifold and the gasket. Discard the nuts and the gasket.

7. NOTE: Note the locations of the 2 long studs.

Remove and discard the 6 LH exhaust manifold studs.

Installation

1. Inspect the LH exhaust manifold gasket mating surfaces for flatness. For additional
information, refer to Section 303-00 .

2. NOTE: Make sure the 2 long studs are installed in the locations noted during removal.

Install 6 new LH exhaust manifold studs.

 Tighten to 12 Nm (9 lb-ft).

3. Position a new LH exhaust manifold gasket and the LH exhaust manifold and install 6 new
nuts.
 Tighten the nuts in the sequence shown to 25 Nm (18 lb-ft).
4. Position the engine lifting eye and install the nuts.
 Tighten to 25 Nm (18 lb-ft).

5. Attach the dual converter Y-pipe and install the 2 nuts.

 Tighten to 40 Nm (30 lb-ft).

6. Connect the HO2S electrical connector.

7. NOTE: Install a new O-ring seal on the oil level indicator tube. Lubricate the O-ring seal with
clean engine oil.

Position the oil level indicator and tube and install the bolt.

 Tighten to 10 Nm (89 lb-in).

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Exhaust Manifold — RH

Item Part Number Description

1 9D477 Exhaust manifold-to-EGR system module tube
2 14A464 Heated oxygen sensor (HO2S) electrical connector
3 9F472 HO2S
4 N800419 Dual converter Y-pipe nuts (2 required)
5 5G218 Dual converter Y-pipe
6 N621939 RH engine lifting eye nuts (2 required)
7 17A084 RH engine lifting eye
8 W701706 RH exhaust manifold nut (6 required)
9 9430 RH exhaust manifold
10 9448 RH exhaust manifold gasket
11 W701768 RH exhaust manifold studs (2 required)
12 N811313 RH exhaust manifold stud (4 required)

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the RH heated oxygen sensor (HO2S). For additional information, refer to Section
303-14 .

3. Detach the exhaust manifold-to-EGR system module tube from the exhaust manifold.

4. Remove the bolts and detach the dual converter Y-pipe.

5. Remove the nuts and the engine lifting eye.

6. Remove the nuts, the RH exhaust manifold and the gasket. Discard the nuts and the gasket.

7. NOTE: Note the locations of the 2 long studs.

Remove and discard the 6 RH exhaust manifold studs.

Installation

1. Inspect the RH exhaust manifold gasket mating surfaces for flatness. For additional
information, refer to Section 303-00 .

2. NOTE: Make sure the 2 long studs are installed in the locations noted during removal.

Install 6 new RH exhaust manifold studs.

 Tighten to 12 Nm (9 lb-ft).

3. Position a new RH exhaust manifold gasket and the RH exhaust manifold and install 6 new
nuts.
 Tighten the nuts in the sequence shown to 25 Nm (18 lb-ft).
4. Position the engine lifting eye and install the nuts.
 Tighten to 25 Nm (18 lb-ft).

5. Attach the dual converter Y-pipe and install the 2 nuts.

 Tighten to 40 Nm (30 lb-ft).

6. Attach the exhaust manifold-to-EGR system module to the exhaust manifold.

 Tighten to 40 Nm (30 lb-ft).

7. Install the RH HO2S. For additional information, refer to Section 303-14 .

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 09/20/2008

Cylinder Head

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket Remover —
ZC-30
Thread Sealant with PTFE WSK-
TA-24 M2G350-A2

Accessory Drive Belt and Generator Bracket

Item Part Number Description

1 8620 Accessory drive belt
2 8678 Accessory drive belt idler pulley
3 N808871 Generator bracket bolt (3 required)
4 N808111 Generator bracket bolt
5 10A313 Generator bracket

RH Cylinder Head

Item Part Number Description

1 W708650 Radio interference capacitor bolt
2 18801 Radio interference capacitor
3 N811497 Cylinder head bolt (short, 4 required)
4 N811496 Cylinder head bolt (long, 4 required)
5 6050 RH cylinder head
6 6051 RH cylinder head gasket

Power Steering Pump and A/C Compressor Bracket

 Part
Item Number Description
1 W710417 A/C compressor and power steering pump bracket
brace nut (2 required)
2 N808113 A/C compressor and power steering pump bracket
bolt (3 required)
3 19D626 A/C compressor and power steering pump bracket
brace
4 19D624 A/C compressor and power steering pump bracket

LH Cylinder Head
 Part
Item Number Description
1 14A464 Cylinder head temperature (CHT) sensor electrical
connector
2 14A464 Knock sensor (KS) electrical connector
3 N811497 Cylinder head bolt (short) (4 required)
4 N811496 Cylinder head bolt (long) (4 required)
5 6050 LH cylinder head
6 6051 LH cylinder head gasket
7 87837 LH cylinder block drain plug

Removal

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 may cause engine failure.

Both cylinder heads

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
 2. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.

3. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive
belt.

RH cylinder head

4. Remove the bolt and the upper idler pulley.

5. Remove the 4 bolts and position the generator bracket, the generator, the accessory drive belt
tensioner and the accessory drive belt idler pulley aside as an assembly.

6. Remove the bolt and position the radio interference capacitor aside.

7. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold — RH
in this section.

8. Detach the heated oxygen sensor (HO2S) electrical connector retainer from the rear of the RH
cylinder head. Remove the bolt and detach the ground wire.

9. Remove the push rods from the RH cylinder head. For additional information, refer to Push
Rod in this section.

LH cylinder head

10. If equipped, remove the A/C compressor. For additional information, refer to Section 412-01 .

11. Remove the 2 A/C compressor and power steering bracket brace nuts.

12. Remove the A/C compressor and power steering bracket brace upper bolt. Loosen the lower
bolt and position it forward until it contacts the power steering pulley. Position the A/C
compressor and power steering bracket brace aside.

13. Loosen the remaining A/C compressor and power steering bracket bolt. Position it forward until
it contacts the power steering pulley and position the A/C compressor and power steering
bracket aside.
 14. Remove the LH exhaust manifold. For additional information, refer to Exhaust Manifold — LH
in this section.

15. Disconnect the knock sensor (KS) and cylinder head temperature (CHT) sensor electrical
connectors. Detach the HO2S electrical connector retainer from the rear of the LH cylinder
head.

16. Remove the push rods from the LH cylinder head. For additional information, refer to Push
Rod in this section.

Both cylinder heads

17. Remove the LH cylinder block drain plug.

18. Remove and discard the 4 short and 4 long cylinder head bolts.

19. Remove the cylinder head and the gasket. Discard the gasket.

Installation

Both cylinder heads

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
that make leak paths. Use a plastic scraping tool to remove all traces of the head
gasket.

NOTE: Observe all warnings or cautions and follow all application directions contained on the
packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean
and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the
cylinder block.

1. Remove any large deposits of silicone or gasket material with a plastic scraper.

2. Apply silicone gasket remover, following package directions and allow to set for
several minutes.

3. Remove the silicone gasket remover with a plastic scraper. A second application of
silicone gasket remover may be required if residual traces of silicone or gasket
material remain.

2. Apply metal surface prep, following package directions, to remove any traces of oil or coolant
and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal
shiny. Some staining of the metal surfaces is normal.

3. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion. For additional information, refer to Section 303-00 .
4. NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry. Failure to follow this instruction may result
in engine damage.

NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.

Position a new cylinder head gasket and the cylinder head.

5. NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are
tighten-to-yield and cannot be reused. Failure to follow this instruction may result in
engine damage.

NOTE: Lubricate the bolts with clean engine oil prior to installation.

Install the new bolts. Make sure the bolts are installed in the correct locations.

1. Install the new long bolts.

2. Install the new short bolts.

6. Tighten the bolts in the sequence shown in 3 stages.

 Stage 1: Tighten to 20 Nm (15 lb-ft).
 Stage 2: Tighten to 40 Nm (30 lb-ft).
 Stage 3: Tighten to 50 Nm (37 lb-ft).
 7. NOTICE: Each bolt must be loosened and the final tightening carried out prior to
working on the next bolt in the sequence. Do not loosen all of the bolts at one time.
Failure to follow this instruction may result in engine damage.

Carry out the following final tightening process on each bolt in the sequence shown.

 Long bolts:
 Loosen and back out 3 turns.
 Tighten to 45 Nm (33 lb-ft).
 Tighten an additional 180 degrees.
 Continue on to the next bolt in the sequence.
 Short bolts:
 Loosen and back out 3 turns.
 Tighten to 25 Nm (18 lb-ft).
 Tighten an additional 180 degrees.
 Continue on to the next bolt in the sequence.

8. Apply thread sealant to the drain plug threads and install the LH cylinder block drain plug.
 Tighten to 32 Nm (24 lb-ft).

LH cylinder head

9. Install the push rods in the LH cylinder head. For additional information, refer to Push Rod in
this section.

10. Connect the KS and CHT electrical connectors. Attach the HO2S electrical connector to the
rear of the LH cylinder head.

11. Install the LH exhaust manifold. For additional information, refer to Exhaust Manifold — LH in
this section.

12. Position the A/C compressor and power steering bracket and loosely install the bolt.

13. Position the A/C compressor and power steering bracket brace and install the 2 bolts. Tighten
all 3 bolts.
 Tighten to 48 Nm (35 lb-ft).

14. Install the A/C compressor and power steering bracket brace nuts.
  Tighten to 25 Nm (18 lb-ft).

15. If equipped, install the A/C compressor. For additional information, refer to Section 412-01 .

RH cylinder head

16. Install the push rods in the RH cylinder head. For additional information, refer to Push Rod in
this section.

17. Attach the HO2S electrical connector retainer to the rear of the RH cylinder head. Position the
ground wire and install the bolt.
 Tighten to 10 Nm (89 lb-in).

18. Install the RH exhaust manifold. For additional information, refer to Exhaust Manifold — RH in
this section.

19. Position the radio interference capacitor and install the bolt.
 Tighten to 10 Nm (89 lb-in).

20. Position the generator bracket, the generator, the accessory drive belt tensioner and the
accessory drive belt idler pulley as an assembly and install the 4 bolts.
 Tighten the 3 lower bolts to 48 Nm (35 lb-ft).
 Tighten the upper bolt to 25 Nm (18 lb-ft).

21. Position the upper idler pulley and install the bolt.
 Tighten the bolt to 55 Nm (41 lb-ft).

Both cylinder heads

22. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.

23. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Oil Level Indicator and Tube

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Item Part Number Description

1 W708650 Oil level indicator tube bolt
2 6754 Oil level indicator tube
3 — Oil level indicator tube O-ring seal
Removal and Installation

1. Remove the bolt and the oil level indicator and tube assembly.
 To install, tighten to 10 Nm (89 lb-in).

2. Remove and discard the O-ring seal.

 To install, apply clean engine oil to the new O-ring seal.

3. To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Engine Lubrication Components — Exploded View

Item Part Number Description

1 636838 Crossmember bolt (4 required)
2 03740415 Crossmember
3 6730 Oil pan drain plug
4 N606087 Oil pan-to-transmission bolt (3 required)
5 N605892 Oil pan bolt (15 required)
6 N804601 Oil pan bolt (2 required)
7 6675 Oil pan
8 6723 Oil pan rear seal
9 W707494 Oil pump screen and pickup tube nut
10 N801689 Oil pump screen and pickup tube bolt (2 required)
11 6622 Oil pump screen and pickup tube
12 W707494 Oil pan baffle nut (5 required)
13 6A835 Oil pan baffle

1. For additional information, refer to the procedures in this section.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Oil Pan

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket and Sealant TA-30 WSE-
M4G323-A4
Silicone Gasket Remover —
ZC-30

Removal

CAUTION: 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 may cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the starter. For additional information, refer to Section 303-06 .

3. Drain the engine oil. Install the drain plug when finished.
 Tighten to 23 Nm (17 lb-ft).

4. Remove the 4 bolts and the crossmember.

5. Remove the 3 oil pan-to-transmission bolts.

6. NOTE: The 2 oil pan-to-engine front cover bolts are unique and must be installed in the correct
positions.

Remove the 17 bolts and the oil pan.

7. Remove and discard the oil pan rear seal.

Installation
1. CAUTION: 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 silicone gasket remover and a plastic scraping tool to
remove all traces of old sealant. Follow the directions on the packaging.

Clean the gasket mating surfaces using silicone gasket remover, a plastic scraping tool and
metal surface prep. Follow the directions on the packaging.

2. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the
sealing areas cleaned. To clean the sealing area, use silicone gasket remover and metal
surface prep. Follow the directions on the packaging. Failure to follow this procedure can
cause future oil leakage.

Apply silicone gasket and sealant to the oil pan sealing areas shown and install the oil pan rear
seal.

1. Apply silicone gasket and sealant to the rear main bearing cap.

2. Install the oil pan rear seal.

3. Apply a bead of silicone gasket and sealant to the oil pan mating surface.
3. NOTE: The 2 oil pan-to-engine front cover bolts are unique and must be installed in the correct
positions.

Position the oil pan and install the bolts. Tighten the bolts in the sequence shown.

 Tighten to 10 Nm (89 lb-in).

4. Install the 3 oil pan-to-transmission bolts.

 Tighten to 34 Nm (25 lb-ft).

5. Install the starter. For additional information, refer to Section 303-06 .

6. Position the crossmember and install the 4 bolts.

 Tighten to 115 Nm (85 lb-ft).

7. Fill the engine with clean engine oil.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Oil Pump Screen and Pickup Tube

Removal and Installation

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.

1. Remove the oil pan. For additional information, refer to Oil Pan in this section.

2. Remove the nut, the bolts, the oil pump screen and pickup tube and the gasket. Discard the
gasket.
 To install, tighten the bolts to 25 Nm (18 lb-ft).
 To install, tighten the nut to 32 Nm (24 lb-ft).

3. 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 silicone gasket remover and a plastic scraping tool to
remove all traces of old sealant. Follow the directions on the packaging.

Clean the gasket mating surfaces using a plastic scraping tool.

4. To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 03/03/2008

Oil Pump

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Item Part Number Description

1 6730 Oil pan drain plug
2 6731 Oil filter
3 N805259 Oil pump large bolt (4 required)
4 N804601 Oil pump small bolt (2 required)
5 6019 Oil pump
6 6C639 Oil pump seal

Removal

CAUTION: 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Drain the engine oil. Install the drain plug when finished.
 Tighten to 23 Nm (17 lb-ft).

3. Remove and discard the oil filter.

4. Remove the 6 bolts and the oil pump.

5. CAUTION: Do not reuse the oil pump seal. A new service seal must be installed.
Failure to follow this instruction may cause future oil leakage.

Remove and discard the oil pump seal.

6. Remove and inspect the oil pump drive gear, the driven gear and the cover. Install new
components if necessary.
 7. Inspect the face of the oil pump for flatness.

Installation

1. Install a new service oil pump seal on the oil pump.

2. NOTE: Lubricate the parts with clean engine oil before assembly.

Install the oil pump drive gear, the driven gear and the cover.
3. Position the oil pump and install the bolts. Tighten the bolts as shown.
1. Tighten to 10 Nm (89 lb-in).

2. Tighten to 28 Nm (21 lb-ft).

4. Install a new oil filter.

 Tighten to 16 Nm (12 lb-ft).

5. Fill the engine with clean engine oil.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View

Item Part Number Description

1 N805018 Flexplate bolt (6 required)
2 N811551 Flywheel bolt (6 required)
3 6375 Flexplate
4 6375 Flywheel
5 6701 Crankshaft rear seal

1. For additional information, refer to the procedures in this section.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Flexplate

Removal and Installation

1. Remove the transmission. For additional information, refer to Section 307-01 .

2. Remove the bolts and the flexplate.

 To install, tighten to 80 Nm (59 lb-ft) in a criss-cross pattern.

3. To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Flywheel

Removal and Installation

1. Remove the clutch. For additional information, refer to Section 308-01 .

2. Remove the bolts and the flywheel.

 To install, tighten to 80 Nm (59 lb-ft) in a criss-cross pattern.

3. To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Crankshaft Rear Seal

Special Tool(s)
Impact Side Hammer
100-001 (T50T-100-A)

Installer, Crankshaft Rear Oil

Seal
303-516 (T95P-6701-BH)

Installer, Crankshaft Rear Oil

Seal
303-561 (T96T-6701-B)

Installer, Crankshaft Rear Oil

Seal (Use only the installer
retaining bolts)
303-518 (T95P-6701-DH)

Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-EH)

Service Set, Crankshaft Rear Oil

Seal (Use only the adapter and
the center jack screw)
303-S560 (T96T-6701-A)

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

1. Remove the flywheel or the flexplate. For additional information, refer to Flywheel or Flexplate
in this section.

2. Using the special tools, remove the crankshaft rear seal.

Installation

1. Clean and inspect the mating surface.

2. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.

Assemble the special tools and the crankshaft rear seal.

3. Install the special tools on the rear of the crankshaft.

4. Install the crankshaft rear seal. Tighten the center jack screw until the spacer contacts the
engine block.

5. Install the flywheel or the flexplate. For additional information, refer to Flywheel or Flexplate in
this section.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 03/03/2008

Engine Support Insulators

Special Tool(s)
3-Bar Engine Support
303-F073

Lifting Bracket, Engine

303-050 (T70P-6000)

Material
Item Specification
Threadlock 262 WSK-M2G351-A6
TA-26

Cooling Fan Shroud

Item Part Number Description
1 N807658 Cooling fan shroud bolts (2 required)
2 8146 Cooling fan shroud

Engine Support Insulators

Item Part Number Description
1 W711403 LH engine support insulator through bolt
2 W711282 LH engine support insulator bolts (2 required)
3 6B032 LH engine support insulator
4 W710384 RH engine support insulator nuts (2 required)
5 6D047 RH engine support insulator washer
6 W711282 RH engine support insulator bolts (2 required)
7 6038 RH engine support insulator

Both sides

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12 .

3. Remove the 5 pushpins and the radiator appearance cover.

4. Remove the bolts and position the fan shroud on the fan.
 To install, tighten to 10 Nm (89 lb-in).

5. Remove the LH engine support insulator through bolt.

 To install, tighten to 350 Nm (258 lb-ft).

6. NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating
surface are free of foreign material and corrosion before installation. Install a new washer.

Remove the RH engine support insulator nuts and washer.

 To install, tighten to 250 Nm (184 lb-ft).

7. Remove the A/C compressor and power steering pump bracket brace upper nut and install the
special tool.
 To install, tighten to 25 Nm (18 lb-ft).

8. NOTE: Use a 10 mm (0.39 in) spring link to connect the Engine Lifting Bracket to the 3-Bar
Engine Support.

Install the special tool and lift the engine approximately 75 mm (3 in).
RH side

9. NOTE: Clean the engine support insulator-to-bracket mating surfaces and the bolt holes in the
bracket of any dirt or foreign material prior to installation.

Remove the bolts and the RH engine support insulator.

 Apply threadlock to the bolt threads prior to installation.

 To install, tighten to 115 Nm (85 lb-ft).

LH side

10. NOTE: Clean the engine support insulator-to-bracket mating surfaces and the bolt holes in the
bracket of any dirt or foreign material prior to installation.

Remove the bolts and the LH engine support insulator.

 Apply threadlock to the bolt threads prior to installation.

 To install, tighten to 115 Nm (85 lb-ft).

Both sides

11. To install, reverse the removal procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
REMOVAL Procedure revision date: 12/09/2008

Engine

Special Tool(s)
Heavy Duty Floor Crane
014-00071

Lifting Bracket, Engine

303-050 (T70P-6000)

Lifting Bracket, Engine

303-F047 (014-00073)

Remover, Spark Plug Wire

303-106 (T74P-6666-A)

Removal

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Release the fuel system pressure. For additional information, refer to Section 310-00 .

3. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

4. Drain the cooling system. For additional information, refer to Section 303-03 .

5. Remove the hood.

 6. Remove the cowl panel grille. For additional information, refer to Section 501-02 .

7. Remove the PCM. For additional information, refer to Section 303-14 .

8. Detach the electrical connector, the wiring harness retainer and the washer hose from the cowl
extension panel.

Vehicles equipped with a manual transmission

9. Remove the pushpins and position the clutch master cylinder reservoir aside. Disconnect the
fuel vapor tubes from the purge valve.

All vehicles

10. Remove the 7 bolts and the cowl extension panel.

11. Remove the 5 pushpins and the radiator sight shield.

12. 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.

Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in
this section.

13. Remove the radiator, the cooling fan and the shroud. For additional information, refer to
Section 303-03 .

14. Remove the air cleaner. For additional information, refer to Section 303-12 .

15. Release the clamp and disconnect the upper radiator hose from the thermostat housing.
Remove the hose from the vehicle.
16. Release the clamps, disconnect the heater hoses and position the heater hoses aside.

17. Release the clamp and disconnect the lower radiator hose from the coolant pump.

18. Disconnect the intake manifold runner control (IMRC) actuator and the fuel charging wiring
harness electrical connectors.
 19. Disconnect the fuel supply spring lock coupling. For additional information, refer to Section
310-00 .

20. Remove the 4 bolts and the fuel rail, the fuel injectors, the fuel charging wiring harness and the
vacuum harness as an assembly.

Vehicles equipped with an automatic transmission

21. Disconnect the fuel vapor tubes from the purge valve.
All vehicles

22. Using the special tool, with a twisting motion, pull the LH spark plug wires off the spark plugs.

23. Detach the LH spark plug wire retainers and remove the LH spark plug wires.

24. Remove the bolts and position the power steering fluid reservoir aside.

25. If equipped, remove the compressor manifold and tube assembly. For additional information,
refer to Section 412-01 .
26. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive
belt.

27. Remove the 2 power steering pump upper bolts.

28. Disconnect the generator.

 Disconnect the electrical connector.
 Slide the protective cap up, remove the nut and disconnect the battery positive cable.
 Detach the wiring harness retainer.
29. Detach the wiring harness retainer.

30. Using the special tool, with a twisting motion, pull the RH spark plug wires off the spark plugs.

31. Detach the RH spark plug wire retainers.

32. Disconnect the coil electrical connector.

33. Remove the bolts, the coil and the RH spark plug wires as an assembly.

34. Disconnect the PCV valve hose from the PCV valve and remove the hose.

35. Disconnect the wiring harness in-line connector.

36. Remove the bolt and detach the ground wire.

37. Detach the wiring harness retainer from the rear of the RH cylinder head.

38. NOTE: The front bolt cannot be removed from the power steering pump with the pressure
hose in place. Remove the rear bolt first, then slide the power steering pump out while
removing the second bolt.

Position the power steering pump aside.

 1. Remove the bolt.

2. Remove the bolt and position the power steering pump aside.

39. Drain the engine oil. Install the drain plug when finished.
 Tighten to 23 Nm (17 lb-ft).

40. Remove the oil filter.

Vehicles equipped with an automatic transmission

41. Detach the transmission cooler tubes from the bracket.

All vehicles

42. Remove the nut and position the starter wiring harness aside.

43. If equipped, disconnect the engine block heater electrical connector.

44. Remove the 4 catalytic converter-to-exhaust manifold nuts.

 45. Remove the starter motor. For additional information, refer to Section 303-06 .

Vehicles equipped with an automatic transmission

46. Remove the cylinder block opening cover.

47. NOTE: Rotate the crankshaft using the crankshaft pulley bolt to access all of the torque
converter nuts.

NOTE: Mark the flexplate and one torque converter stud for installation reference.

Remove the 4 torque converter nuts.

All vehicles

48. Remove the 3 oil pan-to-transmission bolts.

49. Remove the transmission-to-engine bolts.

50. Remove the LH engine support insulator through bolt.

51. Remove the RH engine support insulator nuts.

52. Remove the bolts and the power steering fluid reservoir bracket.

53. Remove the nuts and the RH engine lifting eye.

54. Install the special tool on the RH side of the engine.

55. Remove the nuts and the LH engine lifting eye.

56. Install the special tool on the LH side of the engine.

57. NOTE: Use two 10 mm (3/8 in) spring links to connect the Engine Lifting Bracket 303-F047 to
the Engine Lifting Bracket 303-050.

Install the special tool.

58. Connect an engine crane to the special tool and lift the engine approximately 75 mm (3 in).

59. Remove the bolts and the LH engine support insulator.

 60. Remove the bolts and the RH engine support insulator.

61. Support the transmission with a floor jack and a wood block.

Vehicles equipped with an automatic transmission

62. Remove the engine from the vehicle.

Vehicles equipped with a manual transmission

63. Lift the engine while pulling the engine forward until the alternator pulley is above the radiator
upper support.
64. Rotate the engine 90 degrees to the left and remove the engine from the vehicle.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
DISASSEMBLY Procedure revision date: 12/09/2008

Engine

Special Tool(s)
Impact Slide Hammer
100-001 (T50T-100-A)

Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-EH)

Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D)

Remover, Crankshaft Vibration

Damper
303-176 (T82L-6316-B)

Remover, Oil Seal

303-409 (T92C-6700-CH)

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

NOTE: For additional information, refer to the exploded views under Engine assembly in this section.
Vehicles equipped with a manual transmission

1. NOTICE: Loosen the bolts evenly to prevent pressure plate damage.

NOTE: If the parts are to be reused, mark the clutch pressure plate and the flywheel for
assembly reference.

Remove the 6 bolts, the clutch pressure plate and the clutch disc.

2. Remove the 6 bolts and the flywheel.

Vehicles equipped with an automatic transmission

3. Remove the 6 bolts and the flexplate.

All vehicles

4. Remove the spacer plate.

5. Using the special tools, remove the crankshaft rear seal.

6. Mount the engine on a suitable stand.

7. Disconnect and detach the heated oxygen sensor (HO2S) electrical connector. Remove the
nut and the ground wire.
8. Disconnect the heated PCV valve and the radio interference capacitor electrical connectors.

9. Remove the bolt and the accessory drive belt idler pulley.

10. Remove the 4 bolts and the generator mounting bracket, the generator, the accessory drive
belt tensioner and the idler pulley as an assembly.
11. Disconnect the crankshaft position (CKP) sensor and the camshaft position (CMP) electrical
connectors.
 Detach the 2 wiring harness retainers.

12. If equipped, disconnect the A/C compressor clutch electrical connector and detach the wiring
harness retainer.

13. Remove the 2 nuts, the 2 bolts and the A/C compressor and power steering pump bracket
brace.
14. Remove the bolt and the A/C compressor and power steering pump bracket and, if equipped,
the A/C compressor.

15. Disconnect the oil pressure sender electrical connector and detach the wiring harness retainer.

16. Disconnect and detach the HO2S electrical connector. Disconnect the knock sensor (KS) and
the cylinder head temperature (CHT) sensor electrical connectors.
 Remove the engine wiring harness.
17. Remove the 4 bolts and the coolant pump pulley.

18. Release the clamp and disconnect the bypass hose. Remove the bolt and the heater outlet
tube.

19. 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.
 Remove the 14 bolts and the lower intake manifold.

 Remove and discard the 2 gaskets and 2 end seals.

20. Remove the 3 bolts, 2 stud bolts and the LH valve cover.
 Remove and discard the gasket.

21. Remove the bolt and the oil level indicator and tube.

22. Remove the 6 nuts and the LH exhaust manifold.

  Remove and discard the nuts and the gasket.

23. NOTE: Note the locations of the 2 long studs.

Remove and discard the 6 LH exhaust manifold studs.

24. Remove the bolts and the engine support insulator bracket. Remove the oil pressure sender.

25. Remove the 2 bolts, 3 stud bolts and the RH valve cover.
 Remove and discard the gasket.
26. Remove the 6 nuts and the RH exhaust manifold.
 Remove and discard the nuts and the gasket.

27. NOTE: Note the locations of the 2 long studs.

Remove and discard the 6 RH exhaust manifold studs.

28. Remove the bolts and the RH engine support insulator brackets.

29. NOTE: If the rocker arms are to be reinstalled, they must be installed into their original
positions. Mark the rocker arms for location.

Remove the 6 bolts, the 6 rocker arm pivots and the 6 rocker arms from both cylinder heads.
30. NOTE: If the push rods are to be reinstalled, they must be installed into their original positions.
Mark the push rods for location.

Remove the 6 push rods from both cylinder heads.

31. Remove the 8 cylinder head bolts from both cylinder heads.

32. Remove both cylinder heads.

 Remove and discard both cylinder head gaskets.
33. 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.

Clean the cylinder head gasket surfaces with metal surface cleaner.

34. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion. For additional information, refer to Section 303-00 .

35. NOTE: The 2 oil pan-to-engine front cover bolts are unique and must be installed in the correct
positions.

Remove the 17 bolts and the oil pan.

 Remove and discard the oil pan rear seal.

36. Remove the CMP sensor and the camshaft synchronizer.
1. Remove the 2 bolts and the CMP sensor.

2. Remove the bolt and washer assembly.

3. Remove the camshaft synchronizer.

37. Using the special tool to prevent the crankshaft rotation, remove the crankshaft pulley bolt and
washer.

38. Using the special tools, remove the crankshaft pulley.

39. Using the special tool, remove the crankshaft front seal.
 Discard the crankshaft front seal.

40. Remove the 4 nuts, 4 bolts, the stud bolt, the coolant pump and the gasket.
 Discard the gasket.

41. Remove the engine front cover and oil pump assembly and the engine front cover gasket.
1. Remove the 2 stud bolts.

2. Remove the bolt.

 3. NOTICE: The cap screw is hidden. Make sure to remove it or the engine front
cover will be damaged.

Remove the cap screw.

4. Slide the engine front cover and engine front cover gasket from the dowels.
 Discard the gasket.

5. Remove the studs.

42. Remove the bolt and the camshaft synchronizer drive gear.

43. Compress the timing chain tensioner and install a retaining pin.
44. Remove the crankshaft gear, the camshaft gear and the timing chain as an assembly.

45. Remove the 2 bolts and the timing chain tensioner.

46. NOTE: If the valve tappets are to be reinstalled, they must be installed into their original
locations. Mark the valve tappets for location.

Remove the 12 valve tappets.

1. Remove the 4 bolts.

 2. Remove the valve tappet guide plate and retainer.

3. Remove the 12 valve tappets.

47. Remove the engine balance shaft drive gear and the camshaft key.

48. Remove the 2 bolts and the balance shaft driven gear, thrust plate and engine dynamic
balance shaft as an assembly.

49. Remove the camshaft.

 1. Remove the 2 bolts.

2. Remove the camshaft thrust plate.

3. Remove the spacer.

4. Remove the camshaft.

50. Remove the bearing covers.

1. Remove the engine dynamic balance shaft bearing cover.

2. Remove the camshaft bearing cover.

51. Remove the nut, the 2 bolts and the oil pump screen cover and tube.

52. Remove the 5 nuts and the oil pan baffle.

53. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the
ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the
manufacturer's instructions.
54. NOTICE: The connecting rods and bearings are matched to the crankshaft journals.
Make sure the components are marked and installed in the correct locations, or the
engine may be damaged.

NOTICE: Each connecting rod and connecting rod cap are matched sets. They will fit
together only one way. Mark them before removing and install them in the correct
orientation, or the engine may be damaged.

NOTICE: Do not damage the connecting rod and the connecting rod cap fractured joint
face surface or the engine may be damaged.

Remove the piston.

1. Make sure the piston being removed is at the bottom of the cylinder bore.

2. Remove the 2 bolts.

3. Remove the connecting rod cap and the lower connecting rod bearing.

4. NOTICE: Use care when removing the piston, or the cylinder wall may be
damaged.

Push the piston and the connecting rod out of the cylinder.

55. Repeat the piston removal steps for the remaining pistons.

56. NOTICE: The crankshaft main bearings and the main bearing caps are matched to the
crankshaft journals. Make sure the components are marked and installed in the correct
locations, or the engine may be damaged.

NOTE: The crankshaft main bearing located at the number 3 main bearing cap is the thrust
bearing.

Remove the 4 main bearing caps and lower crankshaft main bearings.

1. Remove the bolts and stud bolts.

2. Remove the 4 main bearing caps and lower crankshaft main bearings.
57. NOTICE: Use care when removing the crankshaft, or the crankshaft journals may be
damaged.

Remove the crankshaft.

58. NOTE: For ease in reassembly, record the locations of the crankshaft upper thrust bearings.

Remove the 3 upper crankshaft main bearings and the crankshaft upper thrust bearing.

59. Remove the camshaft bearings.

60. Remove the engine dynamic balance shaft bearings.

61. If equipped, remove the engine block heater.

62. NOTE: For cleaning purposes, the plugs should be removed.

If necessary, remove the following:

1. Cylinder block dowels.

2. Oil gallery plugs.

3. Water jacket plugs.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 03/03/2008

Cylinder Head

Special Tool(s)
Compressor, Valve Spring
303-163 (T81P-6513-A)

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
Item Part Number Description
1 6518 Valve spring retainer key (24 required)
2 6514 Valve spring retainer (12 required)
3 6513 Valve spring (12 required)
4 6A517 Valve stem seal (12 required)
5 6507 Exhaust valve (6 required)
6 6505 Intake valve (6 required)
7 12405 Spark plug (6 required)
8 6049 Cylinder head (2 required)

Disassembly and Assembly

NOTE: If the components are to be reinstalled, they must be installed in the same position. Mark the
components removed for location.

1. Remove the spark plugs, if necessary.

 To install, tighten to 15 Nm (11 lb-ft).

2. Using the special tool, compress the valve springs.

3. Remove the following:
1. Valve spring retainer keys.

2. Valve spring retainers.

3. Valve springs.

4. Valve stem seals and seats.

5. Exhaust valves.

6. Intake valves.
4. Inspect the components. For additional information, refer to Section 303-00 .

5. CAUTION: Lubricate the parts with clean engine oil before installing. Failure to
follow this instruction may result in component damage.

To assemble, reverse the disassembly procedure.

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 03/03/2008

Piston

Special Tool(s)
Pin Remover/Replacer
303-S024 (T68P-6135-A) or
equivalent

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
Item Part Number Description
1 6150 Piston compression ring, upper
2 6152 Piston compression ring, lower
3 6159 Piston oil control segment ring, upper
4 6161 Piston oil control spacer
5 6159 Piston oil control segment ring, lower
6 6135 Piston pin
7 6200 Connecting rod
8 6108 Piston

Disassembly

1. Remove the piston rings.

2. Using the special tool, press the piston pin out of the connecting rod and piston assembly.
 3. Remove the connecting rod from the piston.

4. Clean and inspect the connecting rod and piston. For additional information, refer to Section
303-00 .

Assembly

1. Lubricate the piston pin and piston pin bore with clean engine oil.

2. NOTE: The connecting rod can be installed in either direction.

Position the piston pin in the bore aligned with the connecting rod bore.

3. Using the special tool, press the piston pin into the piston and rod assembly.
4. Install the piston rings.

5. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced
around the circumference of the piston.
SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
ASSEMBLY Procedure revision date: 12/09/2008

Engine

Special Tool(s)
Alignment Gauge, Synchronizer
303-562

Installer, Crankshaft Front Oil

Seal
303-474 (T94P-6701-AH)

Installer, Crankshaft Rear Oil

Seal
303-516 (T95P-6701-BH)

Installer, Crankshaft Rear Oil

Seal
303-561 (T96T-6701-B)

Installer, Crankshaft Rear Oil

Seal (Use only the installer
retaining bolts)
303-518 (T95P-6701-DH)

Installer, Crankshaft Vibration

Damper
303-175 (T82L-6316-A)
 Installer, Front Cover Oil Seal
303-335 (T88T-6701-A)

Lifting Bracket, Engine

303-050 (T70P-6000)

Lifting Bracket, Engine

303-F047 (014-00073)

Service Set, Camshaft

303-017 (T65L-6250-A)

Service Set, Crankshaft Rear Oil

Seal (Use only the adapter and
the center jack screw)
303-S560 (T96T-6701-A)

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

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft Premium Gold Engine WSS-
Coolant with Bittering Agent (US M97B51-A1
only)
VC-7-B (US); CVC-7-A (Canada);
or equivalent (yellow color)
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Engine Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Brake Caliper Grease and ESE-M1C171-
Dielectric Compound A
XG-3-A
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Silicone Gasket Remover —
ZC-30
Thread Sealant with PTFE WSK-
TA-24 M2G350-A2

Major Upper Engine Components

 Item Part Number Description
1 95498 Vacuum hose assembly
2 9Y456 EGR system module
3 9424 Upper intake manifold
4 9F991 Electronic throttle body
5 9F797 Fuel rail assembly
6 8A520 PCV coolant hose
7 8592 Coolant hose connection
8 8575 Coolant thermostat
9 9439 LH intake manifold gasket
10 9A424 Intake manifold rear seal
11 6010 Cylinder block
12 9278 Oil pressure sensor
13 9A424 Intake manifold front seal
14 9439 RH intake manifold gasket
15 9424 Lower intake manifold

Engine — Front Components

Item Part Number Description
1 6312 Crankshaft pulley
2 8501 Coolant pump
3 8507 Coolant pump housing gasket
4 12A112 Camshaft position (CMP) sensor
5 12A362 Camshaft synchronizer
6 6A618 Oil pump intermediate shaft
7 18663 Heater water outlet tube
8 6020 Engine front cover gasket
9 6C315 Crankshaft position (CKP) sensor
10 6714 Oil bypass filter
11 6019 Engine front cover
12 6010 Cylinder block

Cylinder Heads and Valve Train

Item Part Number Description
1 9D477 EGR valve-to-exhaust manifold tube
2 10039 Generator bracket
3 12029 Ignition coil
4 6A666 PCV valve
5 6582 Valve cover (RH)
6 6758 Crankcase ventilation tube
7 17A084 Engine lifting eye
8 9430 Exhaust manifold (RH)
9 9448 Exhaust manifold gasket (RH)
10 6051 Head gasket (RH)
11 6049 Cylinder head (RH)
12 12280 Ignition wire and bracket (RH)
13 12259 Ignition wire and bracket (LH)
14 6C324 Crankcase vent connector and hose
15 6582 Valve cover (LH)
16 6049 Cylinder head (LH)
17 12405 Spark plug (6 required)
18 17A084 Engine lifting eye
19 9448 Exhaust manifold gasket (LH)
20 9430 Exhaust manifold (LH)
21 6754 Oil level indicator tube
22 6A008 Cylinder heat to block dowel (4 required)
23 6051 Head gasket
24 6010 Cylinder block
25 6565 Push rod (6 required)
26 6564 Rocker arm (6 required)
27 6A528 Rocker arm seat (6 required)
28 N807699 Cylinder head bolt (long) (4 required)
29 6518 Valve spring retainer key (12 required)
30 6514 Valve spring retainer (6 required)
31 6513 Valve spring (6 required)
32 6571 Valve stem seal (6 required)
33 N807324 Cylinder head bolt (short) (4 required)
34 6507 Intake valve (6 required)
35 6505 Exhaust valve (6 required)
Lower End Components
Item Part Number Description
1 6255 Distributor drive gear
2 6268 Timing chain
3 6A303 Engine balance shaft drive gear
4 6A304 Engine balance shaft driven gear
5 6C341 Balance shaft thrust plate
6 6A311 Engine dynamic balance shaft
7 6A333 Balance shaft front and rear bearing (2 required)
8 6K564 Tappet guide plate and retainer (RH)
9 6K564 Tappet guide plate and retainer (LH)
10 6500 Valve tappet (12 required)
11 N805256 Woodruff key
12 6261 Camshaft bearing
13 6306 Crankshaft sprocket
14 6256 Camshaft sprocket
15 6269 Camshaft thrust plate
16 6265 Camshaft sprocket spacer
17 6250 Camshaft
18 6262 Camshaft center bearing (2 required)
19 6263 Camshaft rear bearing
20 6333 Crankshaft main bearing (3 required)
21 6284 Timing chain vibration damper
22 6010 Cylinder block
23 388907 Woodruff key
24 6303 Crankshaft
25 6337 Crankshaft thrust main bearing
26 6266 Camshaft rear bearing cover (2 required)
27 6375 Flywheel or flexplate
28 6A372 Engine rear plate
29 6701 Crankshaft rear oil seal
30 6333 Crankshaft main bearing (3 required)
31 6337 Crankshaft thrust main bearing
32 6329 Main bearing cap
33 6334 Main bearing cap
34 6327 Main bearing cap
35 6325 Rear main bearing cap
36 6A835 Oil pan baffle assembly
37 6723 Oil pan rear seal
38 6626 Oil pump inlet tube gasket
39 6622 Oil pump screen cover and tube
40 6675 Oil pan
41 6150 Piston ring (6 required)
42 6152 Piston ring (6 required)
43 6159 Piston rings (6 required)
44 6161 Piston ring (6 required)
45 6108 Piston
46 6135 Piston pin (6 required)
47 6200 Connecting rod (6 required)
48 6211 Connecting rod bearing (upper) (6 required)
49 6211 Connecting rod bearing (lower) (6 required)
50 6210 Connecting rod cap (6 required)
51 6200 Connecting rod assembly (6 required)
52 6100 Piston and connecting rod assembly (6 required)

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, may cause engine failure.

NOTICE: The moving components must be lubricated with clean engine oil before assembly, or
the engine may be damaged.

NOTICE: The components with oil holes must be correctly aligned with the oil feed holes, or the
engine may be damaged.

All vehicles

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
that make leak paths. Use a plastic scraping tool to remove all traces of old gasket.

NOTE: Observe all warnings or cautions and follow all application directions contained on the
packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean
and prepare the surfaces.

Clean all gasket mating surfaces in the following sequence. Use a plastic scraping tool,
silicone gasket remover, if necessary and metal surface prep. Follow the directions on the
packaging.

1. Remove any large deposits of silicone or gasket material with a plastic scraper.
 2. Apply silicone gasket remover, following package directions and allow to set for
several minutes.

3. Remove the silicone gasket remover with a plastic scraping tool. A second application
of silicone gasket remover may be required if residual traces of silicone or gasket
material remain.

4. Apply metal surface prep, following package directions, to remove any traces of oil or
coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to
make the metal shiny. Some staining of the metal surfaces is normal.

2. If necessary, install the following:

1. Cylinder block dowels.

2. Oil gallery plugs.

3. Water jacket plugs.

3. Using the Camshaft Service Set, install the engine dynamic balance shaft bearings.

4. Using the Camshaft Service Set, install the camshaft bearings.

5. Install the following:
1. Engine dynamic balance shaft bearing cover

2. Camshaft bearing cover

6. If equipped, install the block heater.

 Tighten to 2 Nm (18 lb-in).

7. NOTICE: Make sure the components are installed in the correct locations, or the engine
may be damaged.
 NOTE: Lubricate the crankshaft main bearings with clean engine oil prior to installation.

Install the 3 crankshaft upper main bearings and the crankshaft upper thrust main bearing.

8. NOTICE: Use care when installing the crankshaft, or the crankshaft bearing journals
may be damaged.

Position the crankshaft.

NOTE: The main bearings are precision selective fit. Inspect the bearing clearance. For additional
information, refer to Section 303-00 .

9. NOTE: If the rear main bearing cap is not installed within 4 minutes, remove the sealant and
reapply.

Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket
and sealant to the rear main bearing cap-to-cylinder block parting line.
10. Install the 4 main bearing caps. Tighten the bolts in 2 stages.
 Stage 1: Tighten to 55 Nm (41 lb-ft).
 Stage 2: Rotate an additional 90 degrees.

11. Using a piston ring compressor, compress the piston rings.

12. NOTICE: Use care when installing the connecting rod and piston assemblies, or the
cylinder wall may be damaged.

NOTE: Inspect the piston clearance. For additional information, refer to Section 303-00 .

Install the piston with the arrow on the piston face pointing toward the front of the engine.

13. NOTICE: Each connecting rod and connecting rod cap is a matched set. They will only
fit together one way. Make sure the connecting rod cap is oriented correctly on the
connecting rod or the engine may be damaged.

NOTE: Inspect the connecting rod bearing clearance. For additional information, refer to
Section 303-00 .

Position the lower connecting rod bearing and the connecting rod cap on the connecting rod
and the crankshaft journal.
14. Tighten the 2 connecting rod cap bolts in 3 stages.
 Stage 1: Tighten to 25 Nm (18 lb-ft).
 Stage 2: Tighten to 45 Nm (33 lb-ft).
 Stage 3: Tighten an additional 105 degrees.

15. Install the remaining pistons and the connecting rods.

16. Install the oil pan baffle and the 5 retaining nuts.
 Tighten to 32 Nm (24 lb-ft).
17. Using a new gasket, position the oil pump screen cover and tube and install the 2 bolts and the
nut.
1. Tighten the bolts to 25 Nm (18 lb-ft).

2. Tighten the nut to 32 Nm (24 lb-ft).

18. NOTICE: Use care when installing the camshaft or the camshaft lobes may be damaged.

Install the camshaft, camshaft spacer and camshaft key.

19. Install the camshaft thrust plate and 2 bolts.

 Tighten to 11 Nm (8 lb-ft).
20. Install the engine dynamic balance shaft assembly and 2 bolts.
 Tighten to 11 Nm (8 lb-ft).

21. NOTE: If correctly aligned, the engine dynamic balance shaft timing mark will be at the 6
o'clock position and the camshaft timing mark will be at the 12 o'clock position on the
camshaft.

Install the engine balance shaft drive gear so that the timing mark lines up with the timing mark
on the engine balance shaft driven gear.
22. NOTE: Lubricate the valve tappets with clean engine oil prior to installing. If reusing the valve
tappets, make sure to install them in their original locations.

Install the 12 valve tappets.

 Install the 12 valve tappets.

 Install the tappet guide plates.
 Install the 4 bolts and tighten to 12 Nm (9 lb-ft).

23. Install the timing chain tensioner and 2 bolts.

 Position the timing chain tensioner.
 Install the 2 bolts and tighten to 11 Nm (8 lb-ft).

24. If necessary, compress the tensioner pad and install a retaining pin.
25. Rotate the crankshaft so the No. 1 piston is at top dead center (TDC) and the keyway is at the
12 o'clock position.

26. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.

27. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
28. NOTICE: All timing marks must be aligned with the No. 1 cylinder set on TDC of the
compression stroke or the synchronizer assembly will not be installed correctly,
resulting in incorrect fuel injector timing and possible engine damage.

NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.

Make sure the timing marks and the keyways are aligned.

29. Remove the retaining pin.

30. Install the synchronizer drive gear and the bolt.
 Tighten to 45 Nm (33 lb-ft).

31. NOTE: Use thread sealant with PTFE on studs No. 4 and 6 and bolt No. 12.

Install the engine front cover studs in their original locations.

 Tighten the engine front cover studs to 7 Nm (62 lb-in).

32. NOTE: The coolant pump and gasket must be installed at this time to correctly tighten all of the
engine front cover fasteners in sequence.

Using a new gasket, install the engine front cover.

 Using a new gasket, install the coolant pump.

 Tighten the fasteners in the sequence shown.
 Tighten capscrew No. 12 to 10 Nm (89 lb-in).
 Tighten all other fasteners to 28 Nm (21 lb-ft).
33. NOTE: Lubricate the crankshaft front seal with clean engine oil.

Using the special tools, install the crankshaft front seal.

34. Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper and use
the special tool to install the crankshaft damper.
35. Using the special tool to prevent crankshaft rotation, install the bolt.
 Tighten to 160 Nm (118 lb-ft).

36. NOTICE: After installation, do not loosen the synchronizer bolt and rotate the
synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the
synchronizer bolt after the alignment tool has been removed in order to align the
camshaft position (CMP) electrical connector for any reason. If the electrical connector
is not in the correct position, the synchronizer assembly must be removed and the
alignment tool and the assembly reinstalled if the engine has not been rotated from top
dead center (TDC) of the compression stroke on the No. 1 cylinder. Failure to follow this
procedure will result in incorrect fuel injector timing and possible engine damage.

NOTICE: A synchronizer alignment gauge must be used during the installation of the
synchronizer assembly. Failure to follow this procedure will result in incorrect fuel
injector timing and possible engine damage.

Install the special tool on the camshaft synchronizer by rotating the tool until it engages the
notch in the camshaft synchronizer housing.
37. NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.

NOTE: During installation, the arrow on the special tool will rotate clockwise as the gears
engage.

Install the camshaft synchronizer housing assembly so the arrow on the synchronizer
alignment gauge is 54 degrees from the centerline of the engine.

38. Install the camshaft synchronizer retaining bolt.

 Tighten to 25 Nm (18 lb-ft).
39. Install the camshaft position (CMP) sensor and the 2 bolts.
 Tighten to 6 Nm (53 lb-in).

40. NOTE: If the oil pan is not installed within 4 minutes, remove the sealant and reapply. Use
silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.

1. Apply silicone gasket and sealant to the rear main bearing cap.

2. Install the oil pan rear seal.

3. Apply silicone gasket and sealant to the oil pan sealing surface.
41. NOTE: The 2 oil pan-to-engine front cover bolts are unique and must be installed in the correct
positions.

Tighten the 17 oil pan bolts in the sequence shown.

 Tighten to 10 Nm (89 lb-in).

42. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block
surface and cylinder bore. Failure to follow this instruction may result in engine
damage.

NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry. Failure to follow this instruction may result
in engine damage.

NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.

Using new gaskets, install the RH and the LH cylinder heads.

43. NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are
tighten-to-yield designed and cannot be reused. Failure to follow this instruction may
result in engine damage.

NOTE: Lubricate the bolts with clean engine oil prior to installation.

Install the new bolts. Make sure the bolts are installed in the correct locations.

1. Install the new long bolts.

2. Install the new short bolts.

44. Tighten the bolts in the sequence shown in 3 stages.

 Stage 1: Tighten to 20 Nm (15 lb-ft).
 Stage 2: Tighten to 40 Nm (30 lb-ft).
 Stage 3: Tighten to 50 Nm (37 lb-ft).
45. NOTICE: Each bolt must be loosened and the final tightening carried out prior to
working on the next bolt in the sequence. Do not loosen all of the bolts at one time.
Failure to follow this instruction may result in engine damage.

Carry out the following final tightening process on each bolt in the sequence shown.

 Long bolts:
 Loosen and back out 3 turns.
 Tighten to 45 Nm (33 lb-ft).
 Tighten an additional 180 degrees.
 Continue on to the next bolt in sequence.
 Short bolts:
 Loosen and back out 3 turns.
 Tighten to 25 Nm (18 lb-ft).
 Tighten an additional 180 degrees.
 Continue on to the next bolt in sequence.

46. NOTE: Lubricate the push rods with clean engine oil prior to installation. If reusing the push
rods, make sure to install them in their original locations.

Install the 12 push rods.

47. NOTE: If reusing the rocker arms, make sure to install them in their original locations.

Install the 12 rocker arms.

 Position the 12 rocker arms and pivots.

 Hand-start the 12 bolts.
 Tighten the bolts in 2 stages.
 Stage 1: Tighten to 5 Nm (44 lb-in).
 Stage 2: Tighten to 32 Nm (24 lb-ft).
48. Install the RH engine support insulator bracket and the 3 bolts.
 Tighten to 48 Nm (35 lb-ft).

49. Inspect the RH exhaust manifold gasket sealing surfaces for flatness. For additional
information, refer to Section 303-00 .

50. NOTE: Make sure the 2 long studs are installed in the locations noted during removal.

Install 6 new RH exhaust manifold studs.

  Tighten to 12 Nm (9 lb-ft).

51. Using a new gasket, install the RH exhaust manifold. Loosely install 6 new nuts.

52. Tighten the 6 new nuts in the sequence shown.

 Tighten to 25 Nm (18 lb-ft).

53. Install a new RH valve cover gasket. Position the RH valve cover and install the bolts and stud
bolts.
 Tighten to 10 Nm (89 lb-in).

54. Install the following:

 The LH engine support insulator and the bolts.
 Tighten to 48 Nm (35 lb-ft).
 The oil pressure sender.
 Tighten to 27 Nm (20 lb-ft).
55. Inspect the LH exhaust manifold gasket sealing surfaces for flatness. For additional
information, refer to Section 303-00 .

56. Install 6 new LH exhaust manifold studs.

 Tighten to 12 Nm (9 lb-ft).

57. Using a new gasket, install the LH exhaust manifold. Loosely install 6 new nuts.

58. Tighten the new nuts in the sequence shown.

 Tighten to 25 Nm (18 lb-ft).

59. NOTE: Install a new oil level indicator tube O-ring seal. Lubricate the O-ring seal with clean
engine oil.

Install the oil level indicator tube and the retaining bolt.

 Tighten to 10 Nm (89 lb-in).

60. Install a new valve cover gasket. Position the RH valve cover and install the bolts and stud
bolts.
 Tighten to 10 Nm (89 lb-in).

61. NOTE: If the lower intake manifold is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover
and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure
can cause future oil leakage.

Install the lower intake manifold front and rear seals.

1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear seal
mounting points as indicated.

2. Install the lower intake manifold front and rear seals.

62. Install the intake manifold gaskets.

63. 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.

NOTE: If the lower intake manifold is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover
 and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure
can cause future oil leakage.

Position the lower intake manifold.

1. Apply a bead of silicone gasket and sealant to the lower intake manifold gaskets and
front and rear seal junctions in 4 places as shown.

2. Position the lower intake manifold.

64. NOTE: Make sure the bolts are installed in the correct locations. The long bolts are installed in
positions 1, 2, 3, 4, 11 and 12.

Tighten the 14 bolts in the sequence shown in 2 stages.

 Stage 1: Tighten to 5 Nm (44 lb-in).

 Stage 2: Tighten to 10 Nm (89 lb-in).
65. NOTE: Clean and inspect the O-ring seal. Install a new O-ring seal if necessary. Lubricate the
O-ring seal with clean engine coolant.

Position the heater outlet tube and install the nut. Connect the bypass hose.

 Tighten to 10 Nm (89 lb-in).

66. Position the coolant pump pulley and install the 4 bolts.
 Tighten to 25 Nm (18 lb-ft).
67. Position the engine wiring harness on the engine.

68. Connect and attach the heated oxygen sensor (HO2S) electrical connector. Connect the knock
sensor (KS) and the cylinder head temperature (CHT) sensor electrical connectors.

69. Connect the oil pressure sender electrical connector and attach the wiring harness retainer.

70. Position the A/C compressor and power steering pump bracket and, if equipped, the A/C
compressor and install the bolt finger tight.
71. Position the A/C and power steering pump bracket brace and install the 2 bolts and 2 nuts.
 Tighten the 2 bolts to 48 Nm (35 lb-ft).
 Tighten the 2 nuts to 25 Nm (18 lb-ft).

72. If equipped, attach the wiring harness retainer and connect the A/C compressor clutch
electrical connector.

73. Connect the crankshaft position sensor (CKP) sensor and the camshaft position (CMP)
electrical connectors.
 Attach the 2 wiring harness retainers.
74. Position the generator mounting bracket, the generator, the accessory drive belt tensioner and
the idler pulley as an assembly and install the 4 bolts.
 Tighten the 3 lower bolts to 48 Nm (35 lb-ft).
 Tighten the upper bolt to 25 Nm (18 lb-ft).

75. Install the accessory drive belt idler pulley and the bolt.
 Tighten to 55 Nm (41 lb-ft).

76. Connect the heated PCV valve and the radio interference capacitor electrical connectors.
77. Connect and attach the HO2S electrical connector. Install the ground wire and the nut.

78. Install the special tool on the RH side.

79. Install the special tool on the LH side.

80. NOTE: Use two 10 mm (3/8 in) spring links to connect the Engine Lifting Bracket 303-F047 to
the Engine Lifting Bracket 303-050.

Install the special tool.

81. Attach an engine crane to the Engine Lifting Bracket. Remove the engine from the stand.

82. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.

Assemble the special tools and the crankshaft rear seal.

83. Install the special tools on the rear of the crankshaft.

84. Install the crankshaft rear seal. Tighten the center jack screw (303-S560) until the spacer (303-
561) contacts the engine block.
 85. Install the engine-to-transmission spacer plate.

Vehicles equipped with an automatic transmission

86. NOTE: Tighten the bolts evenly in a criss-cross pattern.

Install the flexplate and the 6 bolts.

 Tighten to 80 Nm (59 lb-ft).

Vehicles equipped with a manual transmission

87. NOTE: Tighten the bolts evenly in a criss-cross pattern.

Position the flywheel and install the 6 bolts.

 Tighten to 80 Nm (59 lb-ft).

88. NOTE: Tighten the bolts evenly in a criss-cross pattern.

NOTE: If reusing the clutch pressure plate and flywheel, make sure the marks made during
disassembly line up.

Position the clutch pressure plate and the clutch disc and install the 6 bolts.

 Tighten to 25 Nm (18 lb-ft).

SECTION 303-01A: Engine — 4.2L 2007 F-150/Mark LT Workshop Manual
INSTALLATION Procedure revision date: 12/09/2008

Engine

Special Tool(s)
Heavy Duty Floor Crane
014-00071

Lifting Bracket, Engine

303-050 (T70P-6000)

Lifting Bracket, Engine

303-F047 (014-00073)

Material
Item Specification
Motorcraft Premium Gold Engine WSS-
Coolant with Bittering Agent (US M97B51-A1
only)
VC-7-B (US); CVC-7-A (Canada);
or equivalent (yellow color)
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Brake Caliper Grease and ESE-M1C171-
Dielectric Compound A
XG-3-A
Threadlock 262 WSK-
TA-26 M2G351-A6

Installation
Vehicles equipped with an automatic transmission

1. NOTE: Make sure the marks made on the torque converter stud and the flexplate are lined up.

Position the engine in the vehicle and mate it to the transmission.

Vehicles equipped with a manual transmission

2. Position the engine with the front of the engine facing the LH side of the vehicle. Lower the
engine until the generator pulley is slightly higher than the radiator upper support.

3. Turn the engine 90 degrees to the right, lower the engine and mate it to the transmission.

All vehicles

4. NOTE: Clean the engine support insulator-to-bracket mating surfaces and the bolt holes in the
bracket of any dirt or foreign material prior to installation.

Install the RH engine support insulator and the bolts.

 Apply threadlock to the bolts threads prior to installation.

 Tighten to 115 Nm (85 lb-ft).
5. NOTE: Clean the engine support insulator-to-bracket mating surfaces and the bolt holes in the
bracket of any dirt or foreign material prior to installation.

Install the LH engine support insulator and the bolts.

 Apply threadlock to the bolts threads prior to installation.

 Tighten to 115 Nm (85 lb-ft).

6. Remove the floor jack and wood block from the transmission.

7. Lower the engine into position and remove the floor crane and the special tools.

8. Position the power steering fluid reservoir bracket and install the bolts.
 Tighten to 20 Nm (15 lb-ft).
9. NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating
surface are free of foreign material and corrosion before installation. Install a new washer.

Install the RH engine support insulator nuts and washer.

 Tighten to 250 Nm (184 lb-ft).

10. Install the LH engine support insulator through bolt.

 Tighten to 350 Nm (258 lb-ft).
 11. Install the transmission-to-engine bolts.
 Tighten to 47 Nm (35 lb-ft).

12. Install the 3 oil pan-to-transmission bolts.

 Tighten to 34 Nm (25 lb-ft).

Vehicles equipped with an automatic transmission

13. NOTE: Rotate the crankshaft using the crankshaft pulley bolt to access all of the torque
converter nuts.

Install the 4 torque converter nuts.

 Tighten to 36 Nm (27 lb-ft).

 14. Install the cylinder block opening cover.

All vehicles

15. Install the starter motor. For additional information, refer to Section 303-06 .

16. Install the 4 catalytic converter nuts.

 Tighten to 40 Nm (30 lb-ft).

17. If equipped, connect the engine block heater electrical connector.

 18. Position the starter wiring harness bracket and install the nut.
 Tighten to 20 Nm (15 lb-ft).

Vehicles equipped with an automatic transmission

19. Attach the transmission cooler tubes to the bracket.

All vehicles

20. Install a new oil filter.

  Tighten to 16 Nm (12 lb-ft).

21. NOTE: Do not tighten the bolts until the 2 upper bolts are installed.

NOTE: Make sure the power steering pressure hose bracket is installed on the stud.

Position the power steering pump and install the bolts finger tight.

1. Slide the power steering pump into position while installing the front bolt.

2. Install the bolt.

22. Attach the wiring harness retainer to the rear of the RH cylinder head.
23. Position the ground wire and install the bolt.

24. Connect the wiring harness in-line connector.

25. Connect the PCV valve hose to the PCV valve.

26. Position the coil and the RH spark plug wires as an assembly and install the bolts.
 Tighten to 7 Nm (62 lb-in).

27. Connect the coil electrical connector.

28. Attach the RH spark plug wire retainers.

29. Apply silicone dielectric compound to the inside of the spark plug wire boots. Connect the
spark plug wires to the spark plugs.
30. Attach the wiring harness retainer.

31. Connect the generator.

 Connect the electrical connector.
 Connect the battery positive cable, install the nut and slide the protective cap over the
terminal.
 Tighten to 8 Nm (71 lb-in).
 Attach the wiring harness retainer.

32. NOTE: Tighten the lower bolts at this time.

Install the power steering pump upper bolts.

 Tighten to 25 Nm (18 lb-ft).

33. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.

34. If equipped, install the compressor manifold and tube assembly. For additional information,
refer to Section 412-01 .

35. Position the power steering fluid reservoir and install the bolts.
 Tighten to 10 Nm (89 lb-in).

36. Position the LH spark plug wires and attach the LH spark plug wire retainers.
 37. Apply silicone dielectric compound to the inside of the spark plug wire boots. Connect the
spark plug wires to the spark plugs.

Vehicles equipped with an automatic transmission

38. Connect the fuel vapor tubes to the purge valve.

All vehicles

39. Position the fuel rail, the fuel injectors, the fuel charging wiring harness and the vacuum
harness as an assembly and install the bolts.
 Tighten to 10 Nm (89 lb-in).
40. Connect the fuel supply spring lock coupling. For additional information, refer to Section 310-
00 .

41. Connect the intake manifold runner control (IMRC) actuator and the fuel charging wiring
harness electrical connectors.

42. Connect the lower radiator hose to the coolant pump.

43. Connect the heater hoses.

44. Connect the upper radiator hose to the thermostat housing.

45. Install the air cleaner. For additional information, refer to Section 303-12 .

46. Install the radiator and the cooling fan and shroud. For additional information, refer to Section
303-03 .

47. 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 upper intake manifold. For additional information, refer to Upper Intake Manifold in
this section.

48. Position the radiator sight shield and install the 5 pushpins.
 49. Position the cowl extension panel and install the 7 bolts.

Vehicles equipped with a manual transmission

50. Connect the fuel vapor tubes to the purge valve. Position the clutch master cylinder reservoir
and install the pushpins.

All vehicles
51. Attach the windshield washer hose, the wiring harness retainer and the electrical connector to
the cowl extension panel.

52. Install the PCM. For additional information, refer to Section 303-14 .

53. Install the cowl panel grille. For additional information, refer to Section 501-02 .

54. Position the hood and install the bolts.

 Tighten to 30 Nm (22 lb-ft).

55. Connect the battery ground cable. For additional information, refer to Section 414-01 .

56. Fill the engine with clean engine oil.

57. Fill and bleed the cooling system. For additional information, refer to Section 303-03 .

58. If equipped, evacuate and charge the A/C system. For additional information, refer to Section
412-00 .