Steps 51-117
NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.
51. Remove the LH and RH timing chain tensioner piston retaining wires.
52. Rotate the crankshaft counterclockwise 120 degrees to Top Dead Center (TDC).
53. CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.
Verify the timing with the following steps.
1 There should be 12 chain links between the camshaft timing marks.
2 There should be 27 chain links between the camshaft and the crankshaft timing marks.
3 There should be 30 chain links between the camshaft and the crankshaft timing marks.
54. Remove the crankshaft damper bolt.
55. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 663099 or "30 RFF" only.
Install the ignition pulse wheel.
56. Install the LH and RH spark plugs.
57. Install new gaskets in the front cover.
58. NOTE: Clean and degrease the sealing surfaces with metal surface cleaner before applying gaskets and sealant.
NOTE: The front cover must be installed and the bolts tightened within four minutes of sealant application.
Apply a 6 mm (0.24 inch) dot of gasket and sealant to the cylinder block-to-lower cylinder block and the cylinder head mating surfaces.
59. NOTE: Fasteners No. 1 and 6 are studs.
Position the front cover and Install the bolts and studs in the sequence shown.
60. NOTE: Clean all sealing surfaces with metal surface cleaner.
NOTE: Lubricate the front crankshaft seal before installation.
Using the special tool, install the crankshaft front oil seal.
61. NOTE: Inspect and install new O-rings as needed.
NOTE: Apply clean engine oil to aid in installation.
Install the coolant tube, the bolt and the stud.
62. Install the oil pressure sensor.
63. Install a new seal on the oil level indicator tube and apply clean engine oil.
64. Install the oil level indicator tube and install the bolt.
65. Apply clean engine oil to the oil filter O-ring and install a new oil filter.
66. NOTE: Clean the keyway and slot using metal surface cleaner before applying gasket sealer.
NOTE: The crankshaft damper must be installed and the bolt tightened within four minutes of sealant application.
Apply gasket and sealant to the end of the crankshaft damper keyway slot.
67. Using the special tool, install the crankshaft vibration damper.
68. Install the special tool to hold the flexplate.
69. Install the crankshaft vibration damper washer and bolt.
- Tighten the bolt in four stages.
- Stage 1: Tighten to 120 Nm (89 ft. lbs.).
- Stage 2: Loosen one full turn (360 degrees).
- Stage 3: Tighten to 50 Nm (37 ft. lbs.).
- Stage 4: Tighten to 90 Nm (66 ft. lbs.).
70. NOTE: The pulley has LH threads.
Install the crankshaft pulley.
71. NOTE: Clean the valve cover sealing area using metal surface cleaner before installing a new gasket.
Install new gaskets in the valve covers.
72. NOTE: Clean the cylinder head and front cover surface using metal surface cleaner before applying silicone gasket and sealant.
NOTE: The valve cover must be installed and the bolts and studs tightened within four minutes of sealant application.
NOTE: LH shown, RH similar.
Apply a 8 mm (0.31 inch) dot of gasket and sealant at the cylinder block-to-front cover mating surface of the LH and RH valve covers.
73. Position the RH valve cover and install the studs in the sequence shown.
74. Position the LH valve cover and install the studs in the sequence shown.
75. Install the coolant pump.
- Position the coolant pump and install the mounting bolts.
- Tighten the bolts in two stages.
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Tighten an additional 90 degrees.
76. Install the heater hose assembly and connect the heater hose to the coolant pump.
77. Connect the coolant pump outlet hose.
78. Connect the Engine Coolant Temperature (ECT) sensor electrical connector and attach the pin-type retainer.
Vehicles with coolant pump belt tensioner
79. Rotate the drive belt tensioner clockwise and install the coolant pump belt.
Vehicles without coolant pump belt tensioner
80. Install the belt on the coolant pump pulley and position it on the camshaft pulley.
81. CAUTION: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.
Rotate the crankshaft clockwise to seat the belt on the camshaft pulley.
All vehicles
82. Install the coolant pump drive belt cover and nuts.
83. Install the coolant tube assembly and connect the two hose clamps.
84. Position the RH exhaust manifold and gasket and install the nuts in the sequence shown.
85. Position the LH exhaust manifold and gasket and install the nuts in the sequence shown.
86. Position the radio interference capacitor and wiring harness conduit and install the nuts.
87. Attach the pin-type retainer.
88. Attach the wiring harness retainer to the stud.
89. NOTE: Clean and inspect the sealing surfaces before installing the gaskets.
Install new gaskets in the lower intake manifold.
90. Position the lower intake manifold and install the bolts in the sequence shown.
91. Connect the fuel injector electrical connectors.
92. Connect the fuel injection pressure and temperature sensor vacuum tube and electrical connector.
93. NOTE: RH shown, LH similar.
NOTE: Apply a film of caliper grease and dielectric compound to the boot prior to installation.
Install the RH and LH ignition coils and the bolts.
94. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
95. Position the Knock Sensor (KS) and install the bolt.
96. Connect the KS electrical connector.
97. Install the differential pressure feedback EGR sensor and bracket.
1 Connect the differential pressure feedback EGR sensor to the vacuum tubes.
2 Position the differential pressure feedback EGR sensor and bracket and install the bolts.
3 Attach the HO2S electrical connector pin-type retainer.
98. Connect the differential pressure feedback EGR sensor and the RH Heated Oxygen Sensor (HO2S) electrical connectors.
99. Connect the coil-on-plug electrical connectors and attach the wiring harness retainers.
100. Install new gaskets in the upper intake manifold, if required.
101. Position the upper intake manifold and install the bolts in the sequence shown.
102. Connect the EGR vacuum regulator solenoid electrical connector.
103. Connect the hose from the Positive Crankcase Ventilation (PCV) valve.
104. Connect the Throttle Position (TP) sensor and Idle Air Control (IAC) valve electrical connectors.
105. Connect the EGR tube to the exhaust manifold.
106. Install the Crankshaft Position (CKP) sensor.
1 Install the sensor.
2 Install the bolt.
3 Connect the electrical connector and clip into place.
107. Connect the oil pressure sensor electrical connector.
108. Connect the harness to the front LH valve cover studs.
109. Connect the Camshaft Position (CMP) sensor electrical connector.
110. Position the A/C compressor bracket and install the bolts.
- Tighten the bolts in two stages.
- Stage 1: Tighten bolts 1 through 5 to 25 Nm (18 ft. lbs.).
- Stage 2: Tighten bolts 1 through 4 an additional 90 degrees.
111. Position the A/C compressor and install the bolts.
112. Connect the A/C compressor.
1 Connect the compressor electrical connector.
2 Connect the pressure sensor electrical connector.
3 Connect the harness to the bracket.
113. Position the power steering pump and install the bolts.
114. Install the generator.
1 Position the generator.
2 Install the studs.
3 Install the bolt.
4 Connect the electrical connector.
115. Rotate the tensioner and install the accessory drive belt.
116. NOTE: RH shown, LH similar.
Install the special tool.
117. NOTE: For out of vehicle repair the transaxle must be installed before the oil pan.
Using the special tools and a suitable engine hoist, remove the engine from the stand.