Part 4

Engine




















a Early build vehicle cooling systems are filled with Motorcraft(R) Specialty Green Engine Coolant and late build vehicle cooling systems are filled with Motorcraft(R) Specialty Orange Engine Coolant. Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.

Lower Engine Block (View 1)










Lower Engine Block (View 2)










Front Engine Block










Cylinder Head










Intake Manifold









NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

96. NOTE: Inspect and install new intake manifold gaskets, if necessary.
Install the intake manifold gaskets, intake manifold and the 7 bolts (3 shown).

- Tighten to 18 Nm (159 lb-in).






97. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

Install new fuel injector O-rings.
- Separate the fuel injectors from the fuel rail.

- Remove and discard the fuel injector O-rings.

- Install new O-rings and lubricate with clean engine oil.

- Install the fuel injectors onto the fuel rail.






98. Install the fuel rail and injector assembly and the 2 stud bolts.
- Tighten to 23 Nm (17 lb-ft).






99. Install the radio capacitor and nut.
- Tighten to 10 Nm (89 lb-in).






100. Install the fuel rail insulator.





101. Position the engine control wiring harness on the engine and connect the CHT (Cylinder Head Temperature) sensor and install the rubber boot.





102. Connect the 4 ignition coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.





103. Connect the 4 fuel injector electrical connectors.
- Attach the 2 wiring harness retainers.






104. Connect the radio capacitor electrical connector.





105. Connect the EGR valve electrical connector.





106. Attach the 2 wiring harness retainers to the intake manifold.





107. Connect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.





108. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.





109. Using a new gasket install the oil filter adapter and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).






110. Connect the Engine Oil Pressure (EOP) switch electrical connector.





111. Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






112. Using new O-ring seals, install the A/C manifold tube and the bolt.
- Tighten to 25 Nm (18 lb-ft).






113. Install 7 new cylinder head studs.
- Tighten to 17 Nm (150 lb-in).






114. Install the new exhaust manifold gasket on the engine.

115. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

NOTE: Make sure to tighten the nuts in the sequence in 2 stages.
Position the exhaust manifold and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages:
- Stage 1: Tighten to 48 Nm (35 lb-ft).

- Stage 2: Tighten to 48 Nm (35 lb-ft).






116. Install the exhaust manifold heat shield and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).






117. Install the exhaust flexible pipe bracket and the 2 bolts.
- Tighten to 35 Nm (26 lb-ft).






118. Install the 2 generator studs.
- Tighten to 24 Nm (18 lb-ft).






119. Install the generator, 2 nuts and 1 bolt.
- Tighten to 47 Nm (35 lb-ft).






120. Connect the Variable Camshaft Timing (VCT) electrical connector and attach the wiring harness retainer to the valve cover stud bolt.





121. Connect the Heated Oxygen Sensor (HO2S) electrical connector and attach the 2 wiring harness retainers to the generator stud bolts.





122. Connect the CKP (Crankshaft Position) sensor electrical connector and attach the wiring harness pin-type retainer.





123. Install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).






124. Install the coolant tube retainer to the intake manifold.





125. Connect the coolant hose to the EGR.





126. Install the accessory drive belt idler pulley and bracket and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).






127. Connect the KS (Knock Sensor) electrical connector and attach the wiring harness pin-type retainer.





128. NOTICE: Make sure the coolant pump is correctly seated to the engine block before installing and tightening the fasteners, or damage to the coolant pump may occur.

NOTE: Clean the coolant pump mating surface with metal surface prep.

NOTE: Lubricate the new coolant pump O-ring with clean engine coolant.
Install the new O-ring, coolant pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).






129. Install the coolant pump pulley and the 3 bolts.
- Tighten to 20 Nm (177 lb-in).






130. Install the accessory drive belt idler pulley.
- Tighten to 25 Nm (18 lb-ft).






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






132. Position the accessory drive belt onto the tensioner and all of the accessory drive pulleys except the coolant pump pulley.

133. Using the hex feature, rotate the accessory drive belt tensioner clockwise and install the accessory drive belt onto the coolant pump pulley.





134. Using the Floor Crane and Spreader Bar, remove the engine from the engine stand.





Vehicles with automatic transaxle

135. Install the flexplate and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).

- Stage 2: Tighten to 80 Nm (59 lb-ft).

- Stage 3: Tighten to 112 Nm (83 lb-ft).






Vehicles with manual transaxle

136. Install the flywheel and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).

- Stage 2: Tighten to 80 Nm (59 lb-ft).

- Stage 3: Tighten to 112 Nm (83 lb-ft).






137. Lubricate the transaxle input shaft pilot bearing with front axle grease.





138. Using the Clutch Disc Aligner, position the clutch disc on the flywheel.





139. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the 6 bolts.

- Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.