Front Cover Installation
NOTE:Carefully remove the plug from the balance shaft bore to prevent debris from getting into the engine.
1. Remove the balance shaft bore plug then install the timing chain tensioner. Tighten the retaining bolts to 8-14 Nm (6-10 lb-ft).
2. Install the timing chain crankshaft sprocket and camshaft sprocket as an assembly.
3. Make sure the timing marks and keyways are aligned. See Figure 21.
4. Apply tension to the timing chain by removing the pick from the tensioner housing.
5. Install the camshaft position sensor drive gear. Tighten the retaining bolt to 40-50 Nm (30-36 lb-ft).
NOTE:
Remember to carefully remove the plugs and rags from the passages and oil pan before installing the new gasket.
6. Apply a light coat of engine oil to all front cover bolt and stud threads. Do not lubricate the capscrew threads or the two stud ends with sealant already applied.
7. Position the new front cover gasket on the engine block.
8. Apply Silicone Gasket and Sealant (F7AZ-19554-EA) or equivalent to the exposed portion of the oil pan.
9. Position the front cover assembly on the engine block.
NOTE:
Some water pump mounting studs are included in the parts kit just in case a stud is damaged during disassembly. All fasteners that are removed from the vehicle may be reused if they are not damaged. If water pump studs 3 and 4 are being reinstalled, apply Pipe Sealant with Teflon(R) (D8AZ-19554-A) or equivalent to the short threaded end of the studs which go into the block. If the kit contains a black-colored stud with part number W701927-S430, DO NOT use this stud. Refer to the Fastener Location Matrix for fastener location and part numbers.
10. Install four (4) water pump studs in the locations shown in Figure 22. The two (2) studs with thread sealer must be installed in the proper positions. Using double nuts, tighten the studs to 7 Nm (62 lb-in). Remove the double nuts after the studs have been tightened.
11. Install the remaining three (3) front cover retaining bolts.
12. Apply Pipe Sealant with Teflon(R) (D8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G350-A2 to the Allen head capscrew, then install the capscrew into the lower part of the front cover.
13. Seat the front cover on the engine block by partially tightening all installed front cover bolts. Do not final tighten the bolts at this time.
14. Position the new water pump gasket on the front cover.
15. Position the water pump on the front cover.
16. Install the water pump retaining bolts.
17. Install stud nuts on all front cover/water pump studs.
NOTE:
The torque specifications in the following step have been revised and are different from those in the service manual.
18. Tighten the front cover/water pump retainers in the sequence shown in Figure 23, to 28 Nm (20 lb-ft). Tighten the Allen head capscrew 11 to 22 Nm (16 lb-ft).
CAUTION
The proper seal installation tools (T94P-6701-AH, T88T-6701-A1 and T82L-6316-A) must be used on the front crankshaft seal. Oil leaks and contamination will result if the proper tools are not used.
19. Install the crankshaft seal in the front cover as follows:
^ Lubricate the crankshaft front oil seal lip with clean engine oil.
^ Place Front Crankshaft Seal Replacer (T94P-6701-AH) and the crankshaft front seal on Front Crankshaft Seal Installer/Aligner (T88T-6701-A1).
^ Place above assembly over the crankshaft.
^ Insert the forcing screw from Damper/Front Cover Seal Replacer (T82L-631 6-A), into Front Crankshaft Seal Installer/Aligner (T88T-6701-A2).
^ Thread the forcing screw into the crankshaft.
^ Hold the forcing screw with a wrench and tighten the draw nut until the flange of the aligner is flush with the front cover surface.
20. Lubricate the crankshaft front oil seal surface on the crankshaft vibration damper with clean engine oil.
21. Apply Silicone Gasket and Sealant (F7AZ-19554-EA) or equivalent to the crankshaft damper keyway.
22. Using Damper/Front Cover Seal Replacer (T82L-6316-A), install the crankshaft damper.
23. Install the crankshaft damper retaining bolt. Tighten the bolt to 140-180 Nm (103-132 lb-ft).
24. Install the crankshaft pulley. Tighten the retainers to 26-38 Nm (19-28 lb-ft).
25. Install the water pump pulley to the water pump. Tighten the retainers to 8-11 Nm (71-101 lb-in).
26. Fill the new engine oil filter with clean 5W-30 engine oil meeting Ford specification WSS-M2C153-G. Lubricate the O-ring then install the filter.
27. Make sure the timing mark on the damper is aligned with the TDC mark on the front cover gauge.
28. Install the camshaft position (CMP) sensor assembly as follows:
^ Make sure the Synchro Positioning Tool (T96T-12200-A) is properly installed on the synchronizer assembly.
^ Insert the camshaft synchronizer assembly in the front cover. Install the synchronizer assembly so that the arrow on the alignment tool is 54 degrees from the centerline of the engine. See Figure 24. This ensures that the CMP sensor electrical connector has proper clearance.
^ Install and tighten the hold-down bolt to 20-30 Nm (15-22 lb-ft).
^ Remove Synchro Positioning Tool.
^ Install the camshaft sensor to the synchronizer assembly. Tighten the retaining screws to 5-8 Nm (45-70 lb-in).
29. Install the power steering pump bracket. Tighten the bolts to 51 Nm (38 lb-ft). Tighten the nuts to 25 Nm (18 lb-ft).
30. Using Steering Pump Pulley Replacer (T65P-3A733-C), install the power steering pump pulley. The pulley face must be flush (within 0.25 mm [0.010 inch]) of the end of the power steering pump shaft.
31. Connect the lower radiator hose to the water pump.
32. Install the coolant recovery bottle into the lower retaining bracket.
33. Install the coolant recovery bottle upper retaining bracket. Tighten all retainers to 9 Nm (80 lb-in).
34. Connect the coolant overflow hose to the radiator.
35. Install the sight shield to the upper radiator support.
36. Connect the upper radiator hose to the thermostat housing.
37. Lubricate the coolant tube O-ring with clean antifreeze.
38. Install the coolant tube to the water pump. Tighten the retaining bolt to 8-11 Nm (71-97 lb-in).
39. Connect the ends of the coolant tube to the coolant hoses on the bulkhead and the center coolant tower.
40. Route the engine wiring harness branches down the front of the engine.
41. Connect connector C131, near the oil pressure sender.
42. Connect the oil pressure sender electrical connector.
43. Attach the wiring harness pushpin to the water pump.
44. Connect the engine coolant temperature sensor electrical connector.
45. Connect the crankshaft sensor and the camshaft sensor electrical connectors.
46. Install the coil pack and the bracket as an assembly. Tighten the retainers to 25 Nm (18 lb-ft).
47. Connect the coil pack and the radio suppressor electrical connectors.
48. Connect all ignition wires to the coil pack.
49. Connect the coolant hose to the left coolant tower.
50. Install the PCV line between the clean air tube and the driver-side valve cover.
51. Install the upper intake manifold gasket.
52 Apply a light coat of Pipe Sealant with Teflon(R) (D8AZ-19554-A) or equivalent to the upper intake manifold retaining bolts and the stud bolt threads.
53. Install the upper intake manifold. Tighten the retainers in the sequence shown in Figure 25, first to 10 Nm (88 lb-in), then to 20 Nm (15 lb-ft), finally to 32 Nm (23 lb-ft).
54. Install the PCV valve to the valve cover.
55. Connect the EGR tube to the EGR valve. Tighten the tube nut to 35-45 Nm (26-33 lb-ft).
56. Position the EVR/EGR transducer bracket assembly near the installed position, then connect the vacuum lines to the EGR transducer.
57. Install the EVR/EGR transducer bracket assembly. Tighten the retainers to 8-11 Nm (71-97 lb-in).
58. Connect the following electrical connectors:
^ EGR transducer
^ EVR solenoid
^ Throttle position sensor
^ Idle air control motor
59. On vehicles equipped with secondary air injection, route the vacuum harness across the engine.
60. On vehicles without secondary air injection, install the vacuum harness on top of the engine.
61. Connect the vacuum lines to the EGR valve and the EVR solenoid.
62. Connect the four (4) vacuum lines to the upper intake manifold.
63. On vehicles equipped with secondary air injection, proceed as follows:
^ Install the air injection diverter valve bracket to the engine. Tighten the retainers securely.
^ Install the ignition wire routing clip to the air injection diverter valve bracket.
^ Position the air injection diverter valve in the installed position, then install the valve retainers. Tighten the retainers to 22-28 Nm (17-20 lb-ft).
^ Connect the vacuum and the electrical connections to the air injection diverter valve solenoid.
^ Install the exhaust tube to the air injection diverter valve. Tighten the tube to 26-34 Nm (20-25 lb ft).
64. On vehicles without secondary air injection, proceed as follows:
^ Install the manifold support bracket to the front of the upper intake manifold. Tighten the retainers securely.
^ Install the ignition wire routing clip to the support bracket.
65. Install the accelerator bracket to the upper intake manifold. Tighten the retainers to 10-14 Nm (91-122 lb-in).
66. Connect the accelerator and the speed control cables to the throttle body.
67. Install the throttle return spring.
68. Connect the clean air tube to the throttle body.
69. Install the drive belt.
70. Raise vehicle on hoist.
71. Drain the engine oil. Tighten the drain plug to 14 Nm (123 lb-in).
72. Lower the vehicle.
73. Connect the battery negative cable, then remove the memory saver.
74. Fill the cooling system, noting the following:
^ The vent plug must be removed from the center coolant tower before the radiator is filled or the engine may not fill completely. See Figure 26.
^ After filling the engine cooling system, add coolant to the vent until full. Tighten the vent plug to 12 Nm (9 lb-ft).
75. Fill the engine with 5W-30 engine oil meeting Ford specification WSS-M2C153-G or equivalent.
76. Disconnect the coil. Prime the lubrication system with fresh oil by cranking the engine for 15 seconds with the coil disconnected or until the oil light turns off or the gauge registers pressure.
77. Reconnect the coil, then start the engine and check for leaks. Allow the engine to warm up to operating temperature, then make sure it is operating properly.