Installation

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

Installation

1. Preparatory operations

CAUTION: Do not damage the cylinder liners. Remove the ring of carbon from the upper edge of the cylinder.

- Remove any gasket residues with Gasket Maker F8AZ-19B508-AB meeting Ford specification WSK-M2G348-A5 and a Spatula.
- Thoroughly clean the threaded bores for the cylinder head bolts.
- Check the cylinder head distortion.





2. Install the cylinder head.
1 Make sure the upright seat of the guide sleeves.
2 Position a new cylinder head gasket onto the cylinder block.
- Attach the cylinder head into the workshop hoist by the lifting eyes and position it on the cylinder block.





3. CAUTION: The cylinder head bolts must not be tightened more than once.

Install the bolts in the sequence shown in three stages:
- Stage 1: Tighten bolt 1 through 10 to 20 Nm.
- Stage 2: Tighten bolt 1 through 10 to 40 Nm.
- Stage 3: Tighten bolt 1 through 10 to 90 degrees.





4. Install the special tools.

NOTE: Use a thumb to press the locating pins of the gasket into the holes.





5. Press a new gasket into the oil feed flange.





6. Prepare the exhaust camshaft for installation.
1 Insert the oil feed ring into the oil feed flange.
2 Slide both components together onto the exhaust camshaft.





7. Thinly coat camshaft bearing cap No. 5 with Silicone Gasket and Sealant F7AZ-19554-EA meeting Ford specification WSE-M4G323-A4.





8. Insert the camshafts.
- Lubricate the valve tappets with Super Premium SAE 5W30 Motor Oil X0-5W30- QSP meeting Ford specification WSS-M2C153-H and insert them.
- Lubricate the camshaft bearings with Super Premium SAE 5W30 Motor Oil XO-5W30- QSP meeting Ford specification WSS-M2C153-11.
- Insert the intake camshaft.
1 Hold the oil feed flange upwards during installation of the exhaust camshaft.
2 Position the oil teed ring hole right to the top.

NOTE: Keep the oil teed flange away from the cylinder head when turning the flange to avoid damaging the gasket.

3 Turn the oil feed flange till the locating lug is in installation position on the cylinder head.
9. Insert new exhaust camshaft oil seal.





10. NOTE: The numbering is on the outside of the camshaft bearing caps.

Insert the camshaft bearing caps.

NOTE: Make sure the upright seat of the exhaust camshaft oil seal during tightening process of camshaft bearing caps.





11. NOTE: Working evenly in several stages, screw in each bolt two turns at a time.

NOTE: Tighten the caps in the indicated sequence.

Tighten the camshaft bearing bolts.





12. Using the special tool, press in the intake camshaft oil seal.





13. NOTE: Location lug of the oil feed flange is in installation position on the cylinder head during installation.

Screw in the oil feed flange bolts and the upper timing case bolts.
- Finger-tighten the right-hand bolt.
- Finger-tighten the left-hand bolt.
1 Tighten the right-hand bolt.
2 Tighten the left-hand bolt.





14. Check that the oil feed ring moves freely.
- If it is difficult to turn the oil feed ring, loosen the bolts on the oil feed flange and tighten them again as described in step





15. NOTE: If the lug is bent not centered between the oil bores and the mark, install a new exhaust camshaft pulley.

Installation position of the exhaust camshaft pulley.
1 The lug is centered between the oil bores and the mark.
2 The lug must locate in the hole.

CAUTION: Do not rotate the crankshaft. Check that it is still resting against the special tool 303-574.





16. NOTE: Install the bolts but do not tighten at this stage.

NOTE: New O-ring seal for the exhaust camshaft pulley.

Slide the camshaft pulleys onto the camshafts, screw in the bolts and position the new timing belt, working counterclockwise.
1 Install the VCT unit bolt finger tight.
2 Install the camshaft pulley bolt finger tight.
17. Install the timing belt.
18. Raise and support the vehicle.





19. Connect the oil pressure switch and the knock sensor electrical connector.





20. Install the brake booster line and the crankcase ventilation hose to the intake manifold.





21. Screw in the lower power steering pump bolts.
22. Position the right-hand front wheel.





23. Install the lower radiator splash shield.
1 Tighten the coolant drain plug.
2 Install the seven bolts.
24. Lower the vehicle.
25. Secure the right-hand front wheel.





26. Install the generator bracket.





27. Install the generator.
1 Install the bolts.
2 Connect the generator electrical connectors.





28. Install the power steering pump.
1 Install the upper power steering pump bolts.
2 Attach the power steering pump bracket to the cylinder head.





29. Install the coolant expansion tank.
- Attach the speed control cable (if equipped) to the coolant expansion tank.





30. Install the pulley cover.





31. Connect the TWC to the exhaust manifold.
32. Connect the H02S electrical connector.





33. Install the exhaust manifold heat shield.
- Insert the oil level indicator tube, and position the coolant hose bracket and the engine lifting eye.
1 Install in the upper bolts.
2 Install the bracket for the tube/hose (A/C).
3 Install the lower bolts.





34. Install the positive crankcase ventilation line clamp.





35. Install the thermostat housing with a new O-ring seal.
1 Connect the CMP sensor electrical connector.
2 Install in the bolts.
3 Connect the coolant hoses.





36. Connect the electrical connectors:
1 Radio interference suppressor.
2 Ignition coil.
3 Engine Coolant Temperature (ECT) sensor.
4 Power Steering Pressure (PSP) switch.





37. Connect the positive lead of the starter motor.

CAUTION: Do not bend the fusible element when tightening the nut as there is a risk of breaking it.

- Install the nut.
- Install the cover.





38. Install the wiring harness rail and connect the vacuum hoses.
- Screw in the upper wiring harness rail bolts.
- Connect the vacuum hoses.
- Connect the cylinder head wiring harness electrical connector.





39. Connect the throttle cable.
- Install the cable in the bracket and slide on the plastic clip.
- Hook the cable in place.





40. Attach the speed control cable.
1 Press the retaining bush into the bracket.

NOTE: An audible click indicates that it has snapped into place.

2 Slide the cable into the retaining bush.
3 Connect the cable to the throttle valve.





41. Install the Air Cleaner (ACL).
- Press the ACL into the rubber mountings.
1 Connect the crankcase ventilation hose.
2 Connect the intake hose.





42. Install the intake pipe.
1 Install the bolt and the two nuts.
2 Connect the plug of the MAF sensor electrical connector.
3 Connect the IAT sensor electrical connector.
43. Fill the cooling system.





44. Tighten the right-hand front wheel.

45. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy.

The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable.
46. Check the fluid levels and correct as necessary.
47. Check the routing of the vacuum hoses and wiring and secure them with Cable ties.

48. NOTE: The engine oil temperature must be at least 80°C. Super Premium SAE 5W30 Motor Oil XO-SW30QSP meeting Ford specification WSS-M2C153-H and oil Filter - change.

49. Check the fluid level again and correct as necessary.