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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1439 (Engine - 2.3L - (Except Hybrid)) >> Assembly >> Engine (Except Block)

Engine (Except Block)

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04618225Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04618226Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04618227Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft
303-465 (T94P-6256-CH)
G04618228Courtesy of FORD MOTOR CO.
 Timing Peg, Crankshaft
303-507
G04618229Courtesy of FORD MOTOR CO.
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G04618230Courtesy of FORD MOTOR CO.
 Adapter for 205-126
(205-072-02)
G04618231Courtesy of FORD MOTOR CO.
 Installer, Front Oil Seal
303-096 (T74P-6150-A)
G04618232Courtesy of FORD MOTOR CO.
 Installer, Crankshaft Rear Main Oil Seal
303-328 (T88P-6701-B1)
G04618233Courtesy of FORD MOTOR CO.
 Aligner, Clutch Disc
308-006 (T71P-7137-H)
MATERIALS

Item Specification
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent WSS-M2C930-A
Metal Surface Cleaner
ZC-21		 WSE-M5B392-A
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent (yellow color) WSS-M97B51-A1
High-Temp 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A ESA-M1C198-A
Fig 1: Identifying Lower Engine Block Components
G04618234Courtesy of FORD MOTOR CO.
Fig 2: Identifying Front Engine Block Components
G04618235Courtesy of FORD MOTOR CO.
Fig 3: Identifying Cylinder Head Components
G04618236Courtesy of FORD MOTOR CO.
Fig 4: Identifying Intake Manifold Components
G04618237Courtesy of FORD MOTOR CO.
CAUTION:
  1. 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 you loosen the pulley bolt. 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.
  2. 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.

    All vehicles 

    WARNING: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  1. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
  2. Remove the engine plug bolt.
    Fig 5: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    3. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
    Fig 6: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  3. Install the special tool.
  4. If removed, install the halfshaft support bracket and bolts.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 7: Locating Halfshaft Support Bracket & Bolts
      G04618240Courtesy of FORD MOTOR CO.
    5. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
  5. Install the oil pump assembly. Tighten the bolts in the sequence shown in 2 stages:
    • Stage 1: Tighten to 10 N.m (89 lb-in).
    • Stage 2: Tighten to 20 N.m (15 lb-ft).
      Fig 8: Identifying Oil Pump Assembly Bolts
      G04618241Courtesy of FORD MOTOR CO.
  6. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 N.m (89 lb-in).
      Fig 9: Locating Pickup Tube & Bolts
      G04618242Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the crankshaft rear main oil seal.
    Fig 10: Identifying Special Tool (303-328)
    G04618243Courtesy of FORD MOTOR CO.
  8. Tighten the crankshaft rear main oil seal bolts in the sequence shown in Fig 11.
    • To install, tighten to 10 N.m (89 lb-in).
      Fig 11: Identifying Crankshaft Rear Main Oil Seal Bolts In Sequence
      G04618244Courtesy of FORD MOTOR CO.
    9. 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 traces of sealant.
  9. Clean and inspect all mating surfaces.
    10. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 12: Identifying Rear Oil Pan Bolts
    G03897723Courtesy of FORD MOTOR CO.
  10. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger tight.
  11. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
    Fig 13: Locating Straight Edge
    G04618246Courtesy of FORD MOTOR CO.
  12. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 14: Identifying Tightening Sequence Of Oil Pan Bolts
      G03897725Courtesy of FORD MOTOR CO.
  13. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 15: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
    14. CAUTION:
    1. 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.
    2. Observe all warnings and 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.
  14. 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.
    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.
  15. Apply silicone gasket and sealant to the locations shown in Fig 16.
    Fig 16: Identifying Silicone Gasket And Sealant Location
    G03897827Courtesy of FORD MOTOR CO.
  16. Install a new head gasket.
    Fig 17: Locating Head Gasket
    G04618250Courtesy of FORD MOTOR CO.
    17. NOTE:
    1. The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    2. Lubricate the bolts with clean engine oil prior to installation.
  17. Install new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
    • Stage 1: Tighten to 5 N.m (44 lb-in).
    • Stage 2: Tighten to 15 N.m (11 lb-ft).
    • Stage 3: Tighten to 45 N.m (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
      Fig 18: Tightening Sequence Of Cylinder Head Bolts
      G04618251Courtesy of FORD MOTOR CO.
    18. CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  18. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages:
    • Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger tight.
    • Stage 2: Tighten to 7 N.m (62 lb-in).
    • Stage 3: Tighten to 16 N.m (12 lb-ft).
      Fig 19: Tightening Sequence Of Camshaft Bearing Cap Bolts
      G04618252Courtesy of FORD MOTOR CO.
    19. NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
  19. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
    • The crankshaft sprocket flange must be facing away from the engine block.
      Fig 20: Locating Crankshaft Sprocket Flange
      G04618253Courtesy of FORD MOTOR CO.
  20. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 21: Locating Oil Pump Chain, Sprocket & Bolt
      G04618254Courtesy of FORD MOTOR CO.
  21. Install the oil pump chain guide and the shoulder bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 22: Locating Oil Pump Chain Guide & Shoulder Bolts
      G04618255Courtesy of FORD MOTOR CO.
  22. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 23: Locating Oil Pump Chain Tensioner
      G04618256Courtesy of FORD MOTOR CO.
    23. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    Fig 24: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  23. Install the special tool in the slots on the rear of both camshafts.
  24. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    Fig 25: Locating Camshaft Sprocket Bolts
    G03897782Courtesy of FORD MOTOR CO.
  25. Install the LH timing chain guide and the bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 26: Identifying Bolts And LH Timing Chain Guide
      G03897780Courtesy of FORD MOTOR CO.
  26. Install the timing chain.
    Fig 27: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  27. Install the RH timing chain guide.
    Fig 28: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    Fig 29: Locating Timing Chain Tensioner Plunger
    G04618262Courtesy of FORD MOTOR CO.
  28. Using the edge of a vise, compress the timing chain tensioner plunger.
  29. Using a small pick, push back and hold the ratchet mechanism.
    Fig 30: Identifying Ratchet Mechanism
    G04618263Courtesy of FORD MOTOR CO.
  30. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 31: Pushing Ratchet Arm Back Into Tensioner Housing
    G04618264Courtesy of FORD MOTOR CO.
  31. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 32: Identifying Paper Clip Into Hole In Tensioner Housing
    G04618265Courtesy of FORD MOTOR CO.
  32. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 N.m (89 lb-in).
      Fig 33: Locating Timing Chain Tensioner & Bolts
      G04618266Courtesy of FORD MOTOR CO.
    33. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  33. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • To install, tighten to 72 N.m (53 lb-ft).
      Fig 34: Locating Camshaft Sprocket Bolts
      G04618267Courtesy of FORD MOTOR CO.
    34. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  34. Clean and inspect the mounting surfaces of the engine and the front cover.
    35. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    Fig 35: Locating Silicone Gasket
    G03897744Courtesy of FORD MOTOR CO.
  35. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the front cover.
  36. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
    • Tighten the 8 mm bolts to 10 N.m (89 lb-in).
    • Tighten the 13 mm bolts to 48 N.m (35 lb-ft).
      Fig 36: Tightening Bolts In Sequence
      G04618269Courtesy of FORD MOTOR CO.
    37. NOTE:
    1. Remove the through-bolt from the special tool.
    2. Lubricate the oil seal with clean engine oil.
    Fig 37: Installing Crankshaft Front Oil Seal Using Special Tool
    G03897717Courtesy of FORD MOTOR CO.
  37. Using the special tool, install a new crankshaft front oil seal.
    38. CAUTION: Do not install the crankshaft pulley bolt at this time.
    NOTE: Apply clean engine oil on the seal area before installing.
    Fig 38: Locating Crankshaft Pulley & Hole
    G04618271Courtesy of FORD MOTOR CO.
  38. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    39. CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
    Fig 39: Locating Crankshaft Pulley Bolt
    G04618272Courtesy of FORD MOTOR CO.
  39. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
  40. Assemble the special tools using 4 hardened washers in the locations shown.
    Fig 40: Assembling Special Tools (205-072-02 And 205-126)
    G04618273Courtesy of FORD MOTOR CO.
    41. CAUTION:
    1. The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.
    2. Do not reuse the crankshaft pulley bolt.
  41. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 N.m (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
      Fig 41: Identifying Special Tools Assembly (205-072-02, 205-126) And Crankshaft Pulley Bolt
      G04618274Courtesy of FORD MOTOR CO.
  42. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 42: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  43. Remove the special tool.
    Fig 43: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  44. Remove the special tool.
    Fig 44: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    45. NOTE: Only turn the engine in the normal direction of rotation.
  45. Turn the crankshaft clockwise 1 and 3/4 turns.
  46. Install the special tool.
    Fig 45: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
    47. NOTE: Only turn the engine in the normal direction of rotation.
    Fig 46: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  47. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
    48. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
  48. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected.
      Fig 47: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
      G03950429Courtesy of FORD MOTOR CO.
  49. Using the special tool, check the position of the camshafts.
    • If it is not possible to install the special tool, the engine valve timing must be corrected.
      Fig 48: Identifying Special Camshaft Tool (303-465)
      G03898006Courtesy of FORD MOTOR CO.
  50. Remove the special tool.
    Fig 49: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    51. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
  51. Install a new CKP sensor.
    • Do not tighten the bolts at this time.
      Fig 50: Locating CKP Sensor
      G03898012Courtesy of FORD MOTOR CO.
    52. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.
  52. Adjust the CKP sensor alignment tool and tighten the bolts.
    • Tighten to 7 N.m (62 lb-in).
      Fig 51: Locating CKP Sensor Bolts
      G04618284Courtesy of FORD MOTOR CO.
  53. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 52: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  54. Remove the special tool.
    Fig 53: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  55. Install the engine plug bolt.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 54: Locating Engine Plug Bolt
      G04319319Courtesy of FORD MOTOR CO.
    56. 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.
  56. Clean the valve cover gasket surface with metal surface cleaner.
  57. Apply silicone gasket and sealant to the locations shown in Fig 55.
    Fig 55: Locating Silicone Gasket Locations
    G04618288Courtesy of FORD MOTOR CO.
    58. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
  58. Install the valve cover.
    • Tighten the bolts in the sequence shown to 10 N.m (89 lb-in).
      Fig 56: Tightening Bolts In Sequence
      G04618289Courtesy of FORD MOTOR CO.
    59. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
  59. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
    • Tighten the CHT sensor to 12 N.m (9 lb-ft).
    • Tighten the spark plugs to 12 N.m (9 lb-ft).
      Fig 57: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs
      G04618290Courtesy of FORD MOTOR CO.
    60. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
  60. Install the coil-on-plugs, bolts and the crankcase vent tube.
    • Tighten to 10 N.m (89 lb-in).
      Fig 58: Locating Coil-On-Plugs, Bolts & Crankcase Vent Tube
      G04618291Courtesy of FORD MOTOR CO.
  61. If equipped, install the block heater.
    • Tighten to 21 N.m (15 lb-ft).
      Fig 59: Locating Block Heater
      G04618292Courtesy of FORD MOTOR CO.
    62. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
  62. Install the crankcase vent oil separator and the KS.
    • Tighten the oil separator bolts to 10 N.m (89 lb-in).
    • Tighten the KS to 20 N.m (15 lb-ft).
      Fig 60: Locating Crankcase Vent Oil Separator & KS
      G04618293Courtesy of FORD MOTOR CO.
  63. Install the coolant hoses.
    Fig 61: Locating Coolant Hoses (1 Of 3)
    G04618294Courtesy of FORD MOTOR CO.
  64. Install the coolant hose.
    Fig 62: Locating Coolant Hoses (2 Of 3)
    G04618295Courtesy of FORD MOTOR CO.
  65. Install the coolant hose.
    Fig 63: Locating Coolant Hoses (3 Of 3)
    G04618296Courtesy of FORD MOTOR CO.
  66. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
    Fig 64: Locating Rubber Boot
    G04618297Courtesy of FORD MOTOR CO.
  67. Attach the wiring harness retainer.
    Fig 65: Locating Wiring Harness Retainer
    G04618298Courtesy of FORD MOTOR CO.
  68. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 66: Locating Coil-On-Plug & Camshaft Position (CMP) Sensor Electrical Connectors
    G04618299Courtesy of FORD MOTOR CO.
  69. Connect the exhaust gas recirculation (EGR) valve and radio interference capacitor electrical connectors. Attach the wiring harness retainer.
    Fig 67: Locating Exhaust Gas Recirculation (EGR) Valve & Radio Interference Capacitor Electrical Connectors
    G04618300Courtesy of FORD MOTOR CO.
  70. Attach the wiring harness retainer.
    Fig 68: Locating Wiring Harness Retainer
    G04618301Courtesy of FORD MOTOR CO.
    71. CAUTION: 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.
  71. 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.
      Fig 69: Locating Fuel Injector O-Ring Seals
      G03885875Courtesy of FORD MOTOR CO.
  72. If originally equipped, position the fuel rail spacers.
    Fig 70: Locating Fuel Rail Spacers
    G04618303Courtesy of FORD MOTOR CO.
  73. Install the fuel rail with the fuel injectors and bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 71: Locating Fuel Rail With Fuel Injectors & Bolts
      G04618304Courtesy of FORD MOTOR CO.
  74. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
    Fig 72: Locating Fuel Injector Electrical Connectors
    G04618305Courtesy of FORD MOTOR CO.
  75. Install the EGR tube.
    • Tighten to 55 N.m (41 lb-ft).
      Fig 73: Locating EGR Tube
      G04618306Courtesy of FORD MOTOR CO.
  76. Position the intake manifold and connect the positive crankcase ventilation hose.
    Fig 74: Locating Positive Crankcase Ventilation Hose
    G04618307Courtesy of FORD MOTOR CO.
    77. NOTE: Inspect and install new intake manifold gaskets, if necessary.
  77. Install the intake manifold gaskets and intake manifold.
    • Tighten the bolts to 18 N.m (13 lb-ft).
      Fig 75: Locating Intake Manifold Gaskets & Intake Manifold
      G04618308Courtesy of FORD MOTOR CO.
  78. Connect the throttle position (TP) sensor electrical connector.
    Fig 76: Locating Throttle Position (TP) Sensor Electrical Connector
    G04618309Courtesy of FORD MOTOR CO.
  79. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    Fig 77: Locating Fuel Rail Pressure, Temperature Sensor Electrical Connector & Vacuum Tube
    G04618310Courtesy of FORD MOTOR CO.
  80. Connect the swirl control valve electrical connector.
    Fig 78: Locating Swirl Control Valve Electrical Connector
    G04618311Courtesy of FORD MOTOR CO.
  81. Connect the idle air control (IAC) motor electrical connector.
    Fig 79: Locating Idle Air Control (IAC) Motor Electrical Connector
    G04618312Courtesy of FORD MOTOR CO.
  82. Connect the temperature manifold absolute pressure (TMAP) electrical connector.
    Fig 80: Locating Temperature Manifold Absolute Pressure (TMAP) Electrical Connector
    G04618313Courtesy of FORD MOTOR CO.
  83. Connect the KS and attach the 2 wiring harness retainers.
    Fig 81: Locating Wiring Harness Retainers (1 Of 2)
    G04618314Courtesy of FORD MOTOR CO.
  84. Attach the 2 wiring harness retainers.
    Fig 82: Locating Wiring Harness Retainers (2 Of 2)
    G04618315Courtesy of FORD MOTOR CO.
  85. If removed, install the capacitor and bolt.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 83: Locating Capacitor & Bolt
      G04618316Courtesy of FORD MOTOR CO.
    86. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
  86. Position the oil filter adapter in a vise and install the oil filter, new oil cooler and oil cooler bolt.
    • Tighten the oil cooler bolt to 34 N.m (25 lb-ft).
    • Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
    87. NOTE:
    1. Early build with oil cooler shown, late build without oil cooler similar.
    2. Clean the gasket mating surfaces with metal surface cleaner.
  87. Install the oil filter adapter with a new gasket and bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 84: Locating Oil Filter Adapter
      G04618317Courtesy of FORD MOTOR CO.
  88. Connect the oil pressure sensor electrical connector.
    Fig 85: Locating Oil Pressure Sensor Electrical Connector
    G04618318Courtesy of FORD MOTOR CO.
    89. NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil prior to installing.
  89. Install the oil level indicator and bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 86: Locating Oil Level Indicator & Bolts
      G04618319Courtesy of FORD MOTOR CO.
    90. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.
  90. Install the thermostat housing and bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 87: Locating Thermostat Housing & Bolts
      G04618320Courtesy of FORD MOTOR CO.
  91. If equipped, connect the oil cooler hoses.
    Fig 88: Locating Oil Cooler Hoses
    G04618321Courtesy of FORD MOTOR CO.
  92. Attach the 2 wiring harness retainers.
    Fig 89: Locating Wiring Harness Retainers
    G04618322Courtesy of FORD MOTOR CO.
  93. Install the engine vacuum tube.
    • Connect the engine vacuum tube.
    • Attach the 2 engine vacuum tube retainers.
      Fig 90: Locating Engine Vacuum Tube
      G04618323Courtesy of FORD MOTOR CO.
    94. NOTE:
    1. Clean the coolant pump mating surface with metal surface cleaner.
    2. Lubricate the coolant pump O-ring with clean engine coolant.
  94. Install the coolant pump and bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 91: Locating Coolant Pump Bolts
      G03897970Courtesy of FORD MOTOR CO.
  95. Install the coolant pump pulley and bolts.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 92: Locating Coolant Pump Pulley Bolts
      G03897969Courtesy of FORD MOTOR CO.
  96. If equipped, install the accessory drive belt idler pulley.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 93: Locating Accessory Drive Belt Idler Pulley (1 Of 2)
      G04618326Courtesy of FORD MOTOR CO.
  97. Install the accessory drive belt idler pulley.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 94: Locating Accessory Drive Belt Idler Pulley (2 Of 2)
      G04618327Courtesy of FORD MOTOR CO.
  98. Install the generator and bolts.
    • Tighten to 47 N.m (35 lb-ft).
      Fig 95: Locating Generator & Bolts
      G04618328Courtesy of FORD MOTOR CO.
  99. Position a new exhaust manifold gasket on the engine.
    100. CAUTION:
    1. Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
    2. Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
    NOTE: Make sure to tighten the nuts in the sequence in 2 stages.
  100. Position the catalytic converter and tighten the 7 exhaust manifold nuts in the sequence shown.
    • Stage 1: Tighten to 47 N.m (35 lb-ft).
    • Stage 2: Tighten to 47 N.m (35 lb-ft).
      Fig 96: Tightening Exhaust Manifold Nuts In Sequence
      G04618329Courtesy of FORD MOTOR CO.
  101. Install the heat shield and the 6 bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 97: Locating Heat Shield & Bolts
      G04618330Courtesy of FORD MOTOR CO.
  102. Install the 2 catalytic converter bracket bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 98: Locating Catalytic Converter Bracket Bolts
      G04618331Courtesy of FORD MOTOR CO.
  103. Connect the generator electrical connections and install the nut.
    • Tighten to 6 N.m (53 lb-in).
      Fig 99: Locating Generator Electrical Connections
      G04618332Courtesy of FORD MOTOR CO.
  104. Connect the CKP sensor electrical connector.
    Fig 100: Locating CKP Sensor Electrical Connector
    G04618333Courtesy of FORD MOTOR CO.
  105. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.

    106. Vehicles with automatic transaxle 

  106. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in 3 stages:
    • Stage 1: Tighten to 50 N.m (37 lb-ft).
    • Stage 2: Tighten to 80 N.m (50 lb-ft).
    • Stage 3: Tighten to 112 N.m (83 lb-ft).
      Fig 101: Identifying Flexplate & Bolts
      G04618334Courtesy of FORD MOTOR CO.

    107. Vehicles with manual transaxle 

  107. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in 3 stages:
    • Stage 1: Tighten to 50 N.m (37 lb-ft).
    • Stage 2: Tighten to 80 N.m (50 lb-ft).
    • Stage 3: Tighten to 112 N.m (83 lb-ft).
      Fig 102: Identifying Flexplate Bolts Tightening Sequence
      G03897718Courtesy of FORD MOTOR CO.
  108. Install the starter motor isolator.
    Fig 103: Locating Starter Motor Isolator
    G04618336Courtesy of FORD MOTOR CO.
  109. Lubricate the transaxle input shaft pilot bearing with front axle grease.
    Fig 104: Locating Transaxle Input Shaft Pilot Bearing
    G04618337Courtesy of FORD MOTOR CO.
  110. Using the special tool, position the clutch disc on the flywheel.
    Fig 105: Positioning Clutch Disc On Flywheel Using Special Tool (308-006)
    G04618338Courtesy of FORD MOTOR CO.
    111. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
  111. Position the clutch pressure plate and install the bolts.
    • Tighten to 27 N.m (20 lb-ft) in a star pattern sequence.
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