Section 1990 (Engine - 3.0L (4V)): Assembly: Engine

Illustration	Tool Name	Tool Number
	Installer, Camshaft Oil Seal	303-464 (T94P-6256-BH)
	Installer, Camshaft Pulley	303-458 (T94P-6312-AH3), part of 303-S455
	Installer, Crankshaft Rear Main Oil Seal	303-178 (T82L-6701-A)
	Installer, Crankshaft Vibration Damper	303-102 (T74P-6316-B)
	Installer, Front Cover Oil Seal	303-335 (T88T-6701-A)
	Installer, Power Steering Pump Pulley	211-185 (T91P-3A733-A)
	Installer Bolts, Crankshaft Rear Main Oil Seal	303-384 (T91P-6701-A)
	Lifting Brackets, Engine	303-050 (T70P-6000)
	Protector, Camshaft Oil Seal	303-463 (T94P-6256-AH)
	Spacer, Water Pump Pulley	303-459 (T94P-6312-AH4), part of 303-S455
	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent

Fig 1: Exploded View Of Engine (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Engine (2 Of 2)

Courtesy of FORD MOTOR CO.

All vehicles 

1. If removed, install the crankshaft key into the keyway on the crankshaft.
Fig 3: Locating Crankshaft Key
Courtesy of FORD MOTOR CO.
2. Install the crankcase cover, a new gasket and the bolts.
   • Tighten to 10 Nm (89 lb-in).
Fig 4: Locating Oil Separator Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
3. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown in 6 stages.
   • Stage 1: Tighten to 40 Nm (30 lb-ft).
   • Stage 2: Tighten to 90 Nm (66 lb-ft).
   • Stage 3: Loosen one full turn.
   • Stage 4: Tighten to 40 Nm (30 lb-ft).
   • Stage 5: Tighten 90 degrees.
   • Stage 6: Tighten 90 degrees.
Fig 5: Identifying Cylinder Heads Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
4. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
Fig 6: Locating Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.
5. Apply clean engine oil to the LH and RH camshaft roller followers.
CAUTION: The camshaft roller followers must be installed in their original positions.
NOTE: RH shown, LH similar.
6. Install the LH and RH camshaft roller followers.
Fig 7: Locating Camshaft Roller Followers
Courtesy of FORD MOTOR CO.
7. Apply clean engine oil to the LH and RH camshafts.
8. Install the LH and RH camshafts.
   • Locate the camshafts as shown.
Fig 8: Locating Camshafts Matching Marks
Courtesy of FORD MOTOR CO.
CAUTION: The camshaft caps must be installed in their original positions or damage to the engine may occur.
CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
9. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
   • Loosely install the bolts.
Fig 9: Locating Camshaft Bearing Caps Installing Sequence
Courtesy of FORD MOTOR CO.
10. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
    • Loosely install the bolts.
Fig 10: Locating Camshaft Bearing Thrust Caps
Courtesy of FORD MOTOR CO.
11. Install the bolts.
    • Tighten in the sequence shown to 8 Nm (71 lb-in).
Fig 11: Identifying Tightening Sequence Of Bolts
Courtesy of FORD MOTOR CO.
CAUTION: The camshaft caps must be installed in their original positions or damage to the engine may occur.
CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
12. Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the bearing caps.
    • Loosely install the bolts.
Fig 12: Locating Camshaft Bearing Caps Installing Sequence
Courtesy of FORD MOTOR CO.
13. Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
    • Loosely install the bolts.
Fig 13: Locating Camshaft Bearing Thrust Caps
Courtesy of FORD MOTOR CO.
14. Install the bolts.
    • Tighten in the sequence shown to 8 Nm (71 lb-in).
Fig 14: Identifying Tightening Sequence Of Bolts
Courtesy of FORD MOTOR CO.
NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
15. Install the camshaft oil seal retainer and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 15: Locating Camshaft Oil Seal Retainer And Bolts
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
16. Using the special tools, install a new camshaft oil seal.
Fig 16: Identifying Special Tools (303-463, 303-464 And 211-185)
Courtesy of FORD MOTOR CO.
CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
17. Install the special tool in the camshaft as shown in the illustration.
    • Adjust the collar on the special tool screw to get the best thread engagement in the rear of the camshaft.
Fig 17: Installing Special Tool On Camshaft
Courtesy of FORD MOTOR CO.
CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-458).
18. Position the coolant pump pulley over the previously installed special tool and on the end of the camshaft. Install the special tools as shown in the illustration.
    • Using the special tools, install a new service coolant pump pulley flush with the end of the camshaft.
Fig 18: Installing Coolant Pump Pulley
Courtesy of FORD MOTOR CO.
19. Remove the crankshaft damper bolt.
Fig 19: Locating Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.
20. Install the crankshaft sprockets with the timing marks out.
Fig 20: Locating Crankshaft Sprockets With Timing Marks Out
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
21. Position the chain tensioner in a soft-jawed vise.
Fig 21: Identifying Chain Tensioner In Soft-Jawed Vise
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
22. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
Fig 22: Holding Chain Tensioner Ratchet Lock Mechanism Away From Ratchet Stem
Courtesy of FORD MOTOR CO.
CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
23. Slowly compress the timing chain tensioner.
24. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
Fig 23: Retaining Tensioner Piston With 1.5-mm (0.06-in) Wire Or Paper Clip
Courtesy of FORD MOTOR CO.
25. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
    1. Mark any link to use as the crankshaft timing mark.
    2. Starting with the crankshaft timing mark, count 29 links and mark the link.
    3. Continue counting to link 42 and mark the link.
Fig 24: Locating Crankshaft & Camshaft Timing Marks On LH & RH Timing Chains
Courtesy of FORD MOTOR CO.
26. Position the LH timing chain and guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
Fig 25: Aligning Marks On Timing Chain With Marks On Camshaft And Crankshaft Sprockets
Courtesy of FORD MOTOR CO.
27. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
    4. Tighten to 25 Nm (18 lb-ft).
Fig 26: Identifying Timing Chain Tensioner Arm & Bolts
Courtesy of FORD MOTOR CO.
28. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
Fig 27: Locating Crankshaft Keyway
Courtesy of FORD MOTOR CO.
29. Verify that the RH camshafts are correctly positioned.
Fig 28: Aligning Marks RH Camshafts
Courtesy of FORD MOTOR CO.
30. Install the RH timing chain and chain guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
Fig 29: Aligning Marks On Timing Chain With Marks On Camshaft And Crankshaft Sprockets
Courtesy of FORD MOTOR CO.
31. Install the RH timing chain tensioner and tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
    4. Tighten to 25 Nm (18 lb-ft).
Fig 30: Identifying Tensioner Arm, Tensioner And Bolts
Courtesy of FORD MOTOR CO.
32. Remove the LH and RH timing chain tensioner piston retaining wires.
33. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.
34. 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.
Fig 31: Checking Chain Links Timing Marks
Courtesy of FORD MOTOR CO.
35. Remove the crankshaft damper bolt.
Fig 32: Identifying Damper Bolt
Courtesy of FORD MOTOR CO.
CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" only (orange in color).
36. Install the ignition pulse wheel.
Fig 33: Identifying Ignition Pulse Wheel
Courtesy of FORD MOTOR CO.
37. Install 3 new gaskets in the front cover.
NOTE: Clean and degrease the sealing surfaces with metal surface prep before applying gasket and sealant.
NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
38. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
Fig 34: Applying Sealant To Cylinder Block
Courtesy of FORD MOTOR CO.
NOTE: Fasteners 1, 8, 13 and 16 are stud bolts.
39. Position the front cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 25 Nm (18 lb-ft).
Fig 35: Identifying Tightening Sequence Of Front Cover Bolts
Courtesy of FORD MOTOR CO.
40. Install the belt tensioner and the bolt.
    • Tighten to 45 Nm (33 lb-ft).
Fig 36: Locating Belt Tensioner & Bolt
Courtesy of FORD MOTOR CO.
41. Install the idler pulley and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 37: Locating Idler Pulley & Bolt
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
42. Using the special tools, install the crankshaft front oil seal.
Fig 38: Installing Crankshaft Seal Using Special Tools (303-335 And 303-102)
Courtesy of FORD MOTOR CO.
NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant.
NOTE: Sealing surfaces must be free of dirt and oil.
NOTE: The crankshaft damper must be installed and the bolt tightened within 4 minutes of sealant application.
43. Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.
Fig 39: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
44. Using the special tool, install the crankshaft vibration damper.
Fig 40: Installing Crankshaft Pulley Using Special Tools (303-102, 303-335)
Courtesy of FORD MOTOR CO.
45. Install the crankshaft vibration damper washer and tighten the bolt in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn (360 degrees).
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten to 90 Nm (66 lb-ft).
Fig 41: Locating Crankshaft Vibration Damper Washer & Bolt
Courtesy of FORD MOTOR CO.
46. Install the knock sensor (KS) and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 42: Locating Knock Sensor (KS) & Bolt
Courtesy of FORD MOTOR CO.
47. Install the oil pressure sender and, if equipped, the block heater.
    • Tighten to 14 Nm (10 lb-ft).
Fig 43: Locating Oil Pressure Sender
Courtesy of FORD MOTOR CO.
48. Position the oil pan baffle. Install the nuts and tighten in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten 45 degrees.
Fig 44: Locating Oil Pan Baffle And Nuts
Courtesy of FORD MOTOR CO.
49. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.
Fig 45: Locating O-Ring Seal
Courtesy of FORD MOTOR CO.
50. Install the oil pump screen and pickup tube.
    1. Position the oil pump screen and pickup tube.
    2. Install the bolts.
    3. Install the nut and tighten in 2 stages.
       • Stage 1: Tighten to 5 Nm (44 lb-in).
       • Stage 2: Tighten 45 degrees.
Fig 46: Identifying Oil Pump Screen, Pickup Tube & Bolts
Courtesy of FORD MOTOR CO.
51. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
Fig 47: Locating O-Ring On Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
52. Position the oil level indicator and tube and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 48: Oil Level Indicator Tube & Nut
Courtesy of FORD MOTOR CO.
53. Install the bypass tube and the nut and bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 49: Locating Coolant Bypass Tube Bolts
Courtesy of FORD MOTOR CO.
54. Position the coolant tube and connect the hoses.
Fig 50: Locating Coolant Tube
Courtesy of FORD MOTOR CO.
55. Install the coolant pump and the bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 51: Locating Coolant Pump & Bolts
Courtesy of FORD MOTOR CO.
56. Connect the hoses.
Fig 52: Locating Hoses
Courtesy of FORD MOTOR CO.
57. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
Fig 53: Locating Coolant Pump Belt On Coolant Pump Pulley
Courtesy of FORD MOTOR CO.
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.
58. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
59. Lubricate the O-ring seal and install the oil filter.
    • Tighten the oil filter 3/4 of a turn after the filter gasket makes contact with the oil filter adapter.
Fig 54: Locating Oil Filter
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

60. Install the halfshaft support bracket and the bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 55: Locating Halfshaft Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
61. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
Fig 56: Locating Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
62. Install a new gasket and the RH exhaust manifold and new nuts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
Fig 57: Right Exhaust Manifold Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.

All vehicles 

63. Install 6 new LH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
Fig 58: Locating Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
64. Install a new gasket and the LH exhaust manifold and new nuts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
Fig 59: Left Exhaust Manifold Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.
CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
65. Install the LH and RH spark plugs.
    • Tighten to 15 Nm (11 lb-ft).
Fig 60: Spark Plugs
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.
NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.
66. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
Fig 61: Applying Silicone Gasket And Sealant At Cylinder Head To Front Cover Mating Surface
Courtesy of FORD MOTOR CO.
NOTE: Install a new valve cover gasket.
67. Position the LH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 62: Identifying Tightening Sequence Of Valve Cover Bolts & Studs
Courtesy of FORD MOTOR CO.
68. Install the engine lift bracket and the bolt.
    • Tighten to 118 Nm (87 lb-ft).
Fig 63: Locating Lift Bracket & Bolt
Courtesy of FORD MOTOR CO.
NOTE: Install a new valve cover gasket.
69. Position the RH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 64: Identifying Tightening Sequence Of Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
70. Install the radio interference capacitor and the nut.
    • Tighten to 6 Nm (53 lb-in).
Fig 65: Locating Radio Interference Capacitor Nut
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.

Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

71. Install the 6 coil-on-plugs and the bolts.
    • Tighten to 6 Nm (53 lb-in).
Fig 66: Coil-On-Plug Bolts
Courtesy of FORD MOTOR CO.
72. Install new gaskets in the lower intake manifold.
NOTE: Install new gaskets.
73. Install the lower intake manifold and the bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 67: Identifying Tightening Sequence Of Lower Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
74. Position the fuel charging wiring harness and connect the fuel injector electrical connectors.
Fig 68: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
75. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
Fig 69: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
76. Connect the crankshaft position (CKP) sensor electrical connector and attach the wiring retainers.
Fig 70: Locating Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
77. Connect the camshaft position sensor (CMP) and oil pressure sensor electrical connectors and attach the wiring retainers.
Fig 71: Locating Camshaft Position Sensor (CMP) & Oil Pressure Sensor Electrical Connectors & Wiring Retainers
Courtesy of FORD MOTOR CO.
78. Connect the LH coil-on-plug electrical connectors and attach the 2 wiring retainers.
Fig 72: Coil-On-Plug Electrical Connectors & Wiring Retainers
Courtesy of FORD MOTOR CO.
79. Connect the radio interference capacitor electrical connector and attach the wiring retainers.
Fig 73: Locating Radio Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
80. Connect the RH coil-on-plug electrical connectors and attach the wiring retainer.
Fig 74: Locating Coil-On-Plug Electrical Connectors & Wiring Retainers
Courtesy of FORD MOTOR CO.
81. Connect the engine coolant temperature (ECT) sensor electrical connector.
Fig 75: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: Install new gaskets.
82. Install the upper intake manifold and the bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 76: Identifying Tightening Sequence Of Upper Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
83. Connect the throttle body coolant hose.
Fig 77: Locating Throttle Body Coolant Hose
Courtesy of FORD MOTOR CO.
84. Connect the vacuum tube fittings to the EGR valve, EGR vacuum regulator and the intake manifold.
Fig 78: Vacuum Tube Fittings At EGR Valve, EGR Vacuum Regulator & Intake Manifold
Courtesy of FORD MOTOR CO.
85. Install the PCV tube.
Fig 79: Locating Positive Crankcase Ventilation (PCV) Tube
Courtesy of FORD MOTOR CO.
86. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors and attach the wiring retainer.
Fig 80: Idle Air Control Valve & Throttle Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
87. Position the engine control wiring harness and install the nuts.
    • Tighten to 6 Nm (53 lb-in).
Fig 81: Locating Engine Control Wiring Harness & Nuts
Courtesy of FORD MOTOR CO.
88. Connect the KS electrical connector.
Fig 82: Locating Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
89. Connect the exhaust gas recirculation (EGR) vacuum regulator electrical connector. Attach the wiring harness retainer and install the nut.
    • Tighten to 10 Nm (89 lb-in).
Fig 83: Locating Exhaust Gas Recirculation (EGR) Vacuum Regulator Electrical Connector
Courtesy of FORD MOTOR CO.
90. Position the heated oxygen sensor (HO2S) electrical connector bracket. Install the nut and attach the wiring retainer.
    • Tighten to 10 Nm (89 lb-in).
Fig 84: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Bracket
Courtesy of FORD MOTOR CO.
91. Attach the engine control sensor wiring connectors to the upper intake manifold.
Fig 85: Locating Engine Control Sensor Wiring Connectors
Courtesy of FORD MOTOR CO.
92. Using the special tools, remove the engine from the engine stand.
Fig 86: Removing Engine From Engine Stand
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the seal lips and seal bore with clean engine oil before installing.
93. Using the special tools, install the crankshaft rear oil seal.
Fig 87: Identifying Special Tools (303-384 And 303-178)
Courtesy of FORD MOTOR CO.
94. Position the flexplate and install the bolts.
    • Tighten to 80 Nm (59 lb-ft).
Fig 88: Locating Flexplate & Bolts
Courtesy of FORD MOTOR CO.