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Removal & Installation: Installation

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NOTE: To achieve proper timing belt tension, camshaft sprocket bolts must be loosened enough to permit sprockets to turn freely on camshafts. With cam sprocket bolts loose and cylinder No. 1 at TDC, crankshaft must be rotated to TDC in clockwise direction (install camshaft alignment tool in cam slots). Cylinders No. 1 and 4 are at TDC when Woodruff key points straight up.
  1. Rotate the crankshaft clockwise to TDC cylinder No. 1. Remove the blanking plug, completely screw in the Crankshaft TDC Timing Peg (303-574, T97-P6000-A), and auto-align the crankshaft to TDC. See Fig 1.
  2. Hold camshafts with open end wrench. Turn the camshafts to ignition position on cylinder No. 4 and insert the Camshaft Alignment Plate (303-465, T94P-6256-CH) onto the ends of both camshafts. See Fig 2.
    3. NOTE: DO NOT kink or bend the timing belt less than a diameter of 1.38" (35 mm). DO NOT rotate the crankshaft, and check that it is still resting against the timing pin. The lug of the belt tensioner must not be hooked into the sheet metal cover during timing belt installation.
  3. Starting from the crankshaft timing belt pulley and working counterclockwise, position a NEW timing belt in place while keeping it under tension. See Fig 3.
  4. Apply tension to the timing belt. Incorrect timing belt tension will cause incorrect valve timing. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover. See Fig 4.
  5. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position. Tighten the attaching bolt (3) enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 0.24" (6 mm) hex key.
  6. Tension the timing belt, working counterclockwise. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment). See Fig 5.
  7. While holding the adjusting washer in position, tighten the bolt to specification. See TORQUE SPECIFICATIONS . DO NOT tighten the camshaft timing pulley bolts against the camshaft alignment plate. Use the camshaft sprocket holding tool to prevent movement. See Figure. The crankshaft must remain at TDC on cylinder No. 1. Tighten the bolts of the intake camshaft timing pulley to specification. Hold the exhaust camshaft by the hexagon with an open end wrench to stop it from turning. Tighten the exhaust camshaft timing belt pulley bolt.
  8. Unscrew and remove crankshaft timing peg. Remove camshaft alignment plate from the camshafts. Turn the crankshaft 2 revolutions in the normal direction of rotation. Check the valve timing by inserting the crankshaft timing peg. Correct it if necessary.
  9. Screw in crankshaft timing peg and make sure that the crankshaft is touching it. Insert camshaft alignment plate into the camshafts. If necessary, loosen the timing pulleys and correct the camshaft alignment. Remove the crankshaft timing peg and camshaft alignment plate. Screw in and tighten the blanking plug on the exhaust camshaft pulley.
    10. NOTE: Coat the inside of the spark plug connectors with silicone grease to a depth of 0.20-0.39" (5-10 mm). Use a blunt object (such as a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connectors.
  10. Attach the PCV hose. Coat the spark plug thread with Never Seize, and screw in the spark plugs. Tighten spark plugs to specification. See TORQUE SPECIFICATIONS . Push in the spark plug connector until it engages. Install appearance cover, and tighten bolts to specification. Connect solenoid valve electrical connector and press in rubber seal. Connect throttle and cruise control cables to appearance cover. Put the upper timing belt cover together with the center timing belt cover in place.
  11. Attach the timing belt center cover/front engine mounting bracket. See Figure. Install the valve cover. See Figure. Tighten the valve cover bolts in 2 stages:
    • Step 1: 18 INCH lbs. (2 N.m).
    • Step 2: 62 INCH lbs. (7 N.m).
    12. NOTE: Check the seating of the timing belt upper cover gasket and correct it if necessary.
  12. Install the timing belt upper cover. See Figure. Install the front engine mount. Connect the Power Assisted Steering (PAS) reservoir. Install the coolant expansion tank.
  13. Install the power steering pipe bracket to the engine lift eye. Install the front support insulator. See Figure. Remove the floor jack.
  14. Install the coolant expansion tank. Attach the cruise control cable (if equipped) to the coolant expansion tank. Raise and support the vehicle.
    15. NOTE: Verify that the center bolt is centered in the support insulator.
  15. Tighten the center bolt of the right engine support insulator. Tighten the center bolt of the left engine support insulator. Install the lower part of the engine front cover. See Figure. Tighten front cover bolts to specification. See TORQUE SPECIFICATIONS .
    16. NOTE: Use the access hole in the bottom of transaxle case to stop engine rotating.
  16. Install the crankshaft pulley/vibration damper and tighten to specification. See TORQUE SPECIFICATIONS . Install the accessory drive belt. See Figure. Note the accessory drive belt direction mark if belt is being reused. Install the belt idler pulley. Install the water pump pulley.
  17. Tension the belt tensioner clockwise, and position the accessory drive belt in place. Tighten the water pump pulley bolts to specification. See TORQUE SPECIFICATIONS .
  18. Install the right front lower splash shield. Install the engine splash shield (if equipped). Lower the vehicle. Install the right front wheel, and tighten nuts to specification. See TORQUE SPECIFICATIONS .
  19. Connect the negative battery cable. Check the fluid levels and correct as necessary. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
  20. When battery is disconnected, some abnormal driveability symptoms may occur until the PCM relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to complete a relearn cycle.
Fig 1: Aligning Crankshaft Timing Marks
G99H54467Courtesy of FORD MOTOR CO.
Fig 2: Installing Camshaft Alignment Tool
G99F54465Courtesy of FORD MOTOR CO.
Fig 3: Identifying Timing Belt Installed Position
G99E54464Courtesy of FORD MOTOR CO.
Fig 4: Applying Pre-Tension To Timing Belt
G98J57215Courtesy of FORD MOTOR CO.
Fig 5: Setting Timing Belt Tension
G98A57216Courtesy of FORD MOTOR CO.
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