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Section 462 (Engine - 3.0L (2V)): Assembly: Engine

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Fig 1: Identifying Special Tools
G03274253Courtesy of FORD MOTOR CO.
MATERIAL SPECIFICATION

Item Specification
Gasket Maker F8AZ-19B508-AB or equivalent WSK-M2G348-A5
Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSE-M4G323-A4
Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent WSS-M2C153-H
Pipe Sealant with Teflon® D8AZ-19554-A or equivalent ESR-M18P7-A
Weatherstrip and Rubber Adhesive E8AZ-19552-A or equivalent ESB-M2G14-A

    ALL VEHICLES 

  1. Install the crankshaft upper main bearings.
    Fig 2: Installing Crankshaft Upper Main Bearings
    G03274254Courtesy of FORD MOTOR CO.
    2. NOTE: Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
    Fig 3: Installing Crankshaft
    G03274255Courtesy of FORD MOTOR CO.
  2. Install the crankshaft.
    3. NOTE: Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with clean engine oil.
    Fig 4: Installing Crankshaft Rear Oil Seal
    G03274256Courtesy of FORD MOTOR CO.
  3. Install the crankshaft rear oil seal.
  4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block.
    Fig 5: Applying Dots Of Gasket Maker Between Rear Bearing Cap And Cylinder Block
    G03274257Courtesy of FORD MOTOR CO.
  5. Install the crankshaft lower main bearings.
    Fig 6: Installing Crankshaft Lower Main Bearings
    G03274258Courtesy of FORD MOTOR CO.
  6. Install the main bearing caps.
    Fig 7: Installing Main Bearing Caps
    G03274259Courtesy of FORD MOTOR CO.
  7. Wedge a large screwdriver at the location shown to hold the crankshaft forward until all the bolts are tightened.
    Fig 8: Identifying Location To Hold Crankshaft Forward
    G03274260Courtesy of FORD MOTOR CO.
  8. Install the bolts.
    • Tighten the bolts in pairs.
    • For crankshaft and crankshaft bearing component tests, refer to ENGINE SYSTEM-GENERAL INFORMATION .
      Fig 9: Installing Bolts
      G03274261Courtesy of FORD MOTOR CO.
  9. If removed, install the camshaft bearings.
    • Use the Camshaft Service Set.
      Fig 10: Installing Camshaft Bearings
      G03274262Courtesy of FORD MOTOR CO.
    10. NOTE: Lubricate the camshaft and the camshaft bearings with clean engine oil.
    Fig 11: Installing Camshaft
    G03274263Courtesy of FORD MOTOR CO.
  10. Install the camshaft.
  11. Install the camshaft retainer.
    Fig 12: Installing Camshaft Retainer
    G03274264Courtesy of FORD MOTOR CO.
  12. Inspect the camshaft end play. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  13. Align the timing marks.
    Fig 13: Aligning Timing Marks
    G03274265Courtesy of FORD MOTOR CO.
  14. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
    Fig 14: Installing Timing Chain, Camshaft Sprocket And Crankshaft Sprocket
    G03274266Courtesy of FORD MOTOR CO.
  15. Install the bolt.
    Fig 15: Installing Bolt
    G03274267Courtesy of FORD MOTOR CO.
    16. NOTE: Lubricate the piston and connecting rod assemblies with clean engine oil.
  16. Install the piston and connecting rod assemblies.
    • Use a piston ring compressor.
      Fig 16: Installing Piston And Connecting Rod Assemblies
      G03274268Courtesy of FORD MOTOR CO.
    17. NOTE: Lubricate the connecting rod bearings with clean engine oil.
  17. Install the connecting rod bearings.
  18. Install the connecting rod caps and nuts.
    • Tighten the nuts in pairs.
      Fig 17: Installing Connecting Rod Caps And Nuts
      G03274269Courtesy of FORD MOTOR CO.
  19. Install the oil pan baffle.
    Fig 18: Installing Oil Pan Baffle
    G03274270Courtesy of FORD MOTOR CO.
  20. Install the oil pump.
    Fig 19: Installing Oil Pump
    G03274271Courtesy of FORD MOTOR CO.
    21. NOTE: Lubricate the valve tappets with clean engine oil.
    Fig 20: Installing Valve Tappets
    G03274272Courtesy of FORD MOTOR CO.
  21. Install the valve tappets.
  22. Install the valve tappet guide plates.
    Fig 21: Installing Valve Tappet Guide Plates
    G03274273Courtesy of FORD MOTOR CO.
  23. Install the valve tappet guide plate retainer.
    Fig 22: Installing Valve Tappet Guide Plate Retainer
    G03274274Courtesy of FORD MOTOR CO.
  24. Install new head gaskets.
    Fig 23: Installing Head Gaskets
    G03274275Courtesy of FORD MOTOR CO.
  25. Install the cylinder heads.
    Fig 24: Installing Cylinder Heads
    G03274276Courtesy of FORD MOTOR CO.
  26. Install the bolts. Tighten the bolts in the sequence shown in five stages.
    • Stage 1: Tighten the bolts to 50 N.m (37 lb-ft).
    • Stage 2: Loosen the bolts one full turn.
    • Stage 3: Tighten to 30 N.m (22 lb-ft).
    • Stage 4: Tighten the bolts 90 degrees.
    • Stage 5: Tighten the bolts an additional 90 degrees.
      Fig 25: Head Bolts Tightening Sequence
      G03274277Courtesy of FORD MOTOR CO.
  27. Install the oil bypass filter.
    Fig 26: Installing Oil Bypass Filter
    G03274278Courtesy of FORD MOTOR CO.
  28. Install the oil level indicator tube.
    Fig 27: Installing Oil Level Indicator Tube
    G03274279Courtesy of FORD MOTOR CO.
    29. CAUTION: All timing marks must be aligned with the No. 1 cylinder set on top dead center (TDC) of the compression stroke or the synchronizer assembly will not be installed correctly.
    NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.
    Fig 28: Aligning Timing Marks
    G03274280Courtesy of FORD MOTOR CO.
  29. Align the timing marks.
  30. Install a new engine front cover gasket and the engine front cover.
    Fig 29: Installing A New Engine Front Cover Gasket And Engine Front Cover
    G03274281Courtesy of FORD MOTOR CO.
  31. Apply pipe sealant with Teflon® on the bolts to be installed in the locations shown.
    Fig 30: Identifying Bolt Locations Requiring Applying Pipe Sealant
    G03274282Courtesy of FORD MOTOR CO.
  32. Install the bolts.
    Fig 31: Installing Bolts
    G03274283Courtesy of FORD MOTOR CO.
  33. Install the crankshaft position (CKP) sensor.
    Fig 32: Installing CKP Sensor
    G03274284Courtesy of FORD MOTOR CO.
    34. CAUTION: The thickness of the sealant must be between 4-6 mm (0.16-0.23 inch) or oil leaks could occur.
    NOTE: The oil pan should be installed and tightened to specification within four minutes of the sealant application or oil leaks can occur.
    Fig 33: Applying Sealant To Junction Of Rear Main Bearing Cap & Timing Cover Junctions
    G03274285Courtesy of FORD MOTOR CO.
  34. Apply a 4.0-6.0 mm (0.16-0.23 inch) bead of silicone gasket and sealant to the junction of the rear main bearing cap and the cylinder block, and to the junction of the front cover assembly and cylinder block.
  35. Position the oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with the gasket clips.
    Fig 34: Positioning Oil Pan Gasket To Oil Pan
    G03274286Courtesy of FORD MOTOR CO.
    36. NOTE: Make sure the fasteners are clean and dry prior to installation.
    Fig 35: Oil Pan Bolts Tightening Sequence
    G03274287Courtesy of FORD MOTOR CO.
    CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from TDC of the compression stroke on the No. 1 cylinder.
  36. Tighten the oil pan bolts to 12 N.m (9 lb-ft) in the sequence shown.
    37. CAUTION: A synchronizer alignment gauge must be used during the installation of the synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possible causing engine damage.
    Fig 36: Installing Special Tool (303-589) On Camshaft Synchronizer
    G03274288Courtesy of FORD MOTOR CO.
  37. Install the special tool (303-589) on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
    38. NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.
    NOTE: During installation, the arrow on the special tool will rotate clockwise as the gears engage.
    Fig 37: Installing Camshaft Synchronizer Housing Assembly
    G03274289Courtesy of FORD MOTOR CO.
  38. Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment gauge is 38 degrees from the centerline of the engine.
  39. Install the camshaft synchronizer retaining bolt.
    Fig 38: Installing Camshaft Synchronizer Retaining Bolt
    G03274290Courtesy of FORD MOTOR CO.
  40. Install the camshaft position (CMP) sensor.
    Fig 39: Installing CMP Sensor
    G03274291Courtesy of FORD MOTOR CO.
  41. Apply four beads of silicone gasket and sealant.
    Fig 40: Identifying Beads Of Silicone Gasket And Sealant
    G03274292Courtesy of FORD MOTOR CO.
  42. Install the intake manifold gaskets and end seals.
    • Position the end seals.
    • Position the intake manifold gaskets.
      Fig 41: Installing Intake Manifold Gaskets And End Seals
      G03274293Courtesy of FORD MOTOR CO.
  43. Install the lower intake manifold.
    • Tighten the bolts in the sequence shown.
      Fig 42: Lower Intake Bolts Tightening Sequence
      G03274294Courtesy of FORD MOTOR CO.
  44. Install the push rods and the rocker arms.
    • Install the push rods.
    • Install the rocker arms.
    • Tighten the rocker arm bolts.
      Fig 43: Installing Push Rods And Rocker Arms
      G03274295Courtesy of FORD MOTOR CO.
  45. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
    Fig 44: Applying A Bead Of Silicone Gasket And Sealant To Intake-To-Cylinder Head Seams
    G03274296Courtesy of FORD MOTOR CO.
  46. If removed, install the valve cover gaskets.
    Fig 45: Installing Valve Cover Gaskets
    G03274297Courtesy of FORD MOTOR CO.
  47. Install the valve covers and bolts
    • Tighten the bolts in the sequence shown.
      Fig 46: Valve Covers Bolts Tightening Sequence
      G03274298Courtesy of FORD MOTOR CO.
  48. Position the engine control sensor wiring and connect:
    • The CMP sensor.
    • The fuel injectors.
    • The water temperature indicator sender unit.
    • The engine control sensor wiring.
      Fig 47: Positioning/Connecting Engine Control Sensor Wiring
      G03274299Courtesy of FORD MOTOR CO.
  49. Using the Crankshaft Vibration Damper Installer, install the crankshaft damper.
    Fig 48: Installing Crankshaft Damper
    G03274300Courtesy of FORD MOTOR CO.
  50. Install the bolt.
    Fig 49: Installing Crankshaft Damper Bolt
    G03274301Courtesy of FORD MOTOR CO.
  51. Install the bolts and the crankshaft pulley.
    Fig 50: Installing Crankshaft Pulley
    G03274302Courtesy of FORD MOTOR CO.
  52. Install the coolant pump pulley and the bolts.
    Fig 51: Installing Coolant Pump Pulley Bolts
    G03274303Courtesy of FORD MOTOR CO.
  53. Install the generator mounting bracket and the bolts.
    Fig 52: Installing Generator Mounting Bracket Bolts
    G03274304Courtesy of FORD MOTOR CO.
  54. Position the ignition coil assembly and install the bolts.
    Fig 53: Installing Ignition Coil Assembly
    G03274305Courtesy of FORD MOTOR CO.
  55. Connect the ignition coil.
    Fig 54: Connecting Ignition Coil
    G03274306Courtesy of FORD MOTOR CO.
  56. Connect the spark plug wires. For additional information, refer to ENGINE IGNITION - 3.0L (2V) .
  57. Install the Lifting Eyes and the lifting equipment.
  58. Remove the engine from work stand.
  59. Install the engine-to-transmission spacer plate.
  60. Install the flywheel or flexplate.
    Fig 55: Installing Flywheel Or Flexplate
    G03274307Courtesy of FORD MOTOR CO.

    61. VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION 

  61. Adjust the clutch pressure plate.
    1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
    2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
    3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
      Fig 56: Adjusting Clutch Pressure Plate
      G03274308Courtesy of FORD MOTOR CO.
  62. Using the special tool, position the clutch disc on the flywheel.
    Fig 57: Positioning Clutch Disc On Flywheel
    G03274309Courtesy of FORD MOTOR CO.
    63. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
    Fig 58: Installing Clutch Pressure Plate
    G03274310Courtesy of FORD MOTOR CO.
  63. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern.
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