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Section 458 (Engine - 3.0L 4V): Assembly: Engine

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tool (1 Of 3)
G01593125Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tool (2 Of 3)
G01593126Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tool (3 Of 3)
G01593127Courtesy of FORD MOTOR CO.
Fig 4: Identifying Material Specifications
G01593128Courtesy of FORD MOTOR CO.
    WARNING: Eye protection is required to be worn during the use of compressed air. Failure to wear eye protection could result in possible personal injury.
  1. Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.
  2. If removed, install the crankshaft key into the keyway on the crankshaft.
    Fig 5: Installing Crankshaft Key Into Keyway On Crankshaft
    G01593129Courtesy of FORD MOTOR CO.
    3. NOTE: This procedure is for selecting bearings using a new crankshaft.
    Fig 6: Locating Codes On Crankshaft Flange And Cylinder Block Rear Face
    G01593130Courtesy of FORD MOTOR CO.
  3. Select the crankshaft main bearings for each crankshaft journal.
    1. Read the code on the crankshaft flange.
    2. Read the code on the cylinder block rear face.
    • The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2.
    • The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.
  4. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
    • For example: If the block code is *0609*0711* and the crankshaft code is *8580*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 85 crankshaft row. Mains 2, 3 and 4 should all be grade 2.
    Fig 7: Reference Chart For Selecting Crankshaft Bearing
    G01593131Courtesy of FORD MOTOR CO.
  5. Install the main bearings into the cylinder block.
    Fig 8: Installing Main Bearings Into Cylinder Block
    G01593132Courtesy of FORD MOTOR CO.
  6. Install the main bearings into the lower cylinder block.
    Fig 9: Installing Main Bearings Into Lower Cylinder Block
    G01593133Courtesy of FORD MOTOR CO.
  7. Install the crankshaft thrust bearing.
    Fig 10: Installing Crankshaft Thrust Bearing
    G01593134Courtesy of FORD MOTOR CO.
  8. If removed, install the crankshaft key.
    Fig 11: Installing Crankshaft Key
    G01593135Courtesy of FORD MOTOR CO.
  9. Apply engine oil to the crankshaft main and rod bearing journals.
    10. CAUTION: The lower cylinder block must be installed and the bolts tightened within four minutes of applying the sealant.
    NOTE: Clean and degrease both surfaces using metal surface cleaner before applying sealant.
    Fig 12: Identifying Locations For Applying Gasket And Sealant
    G01593136Courtesy of FORD MOTOR CO.
  10. Apply gasket and sealant to the cylinder block as shown.
  11. Position the crankshaft in the cylinder block.
    Fig 13: Positioning Crankshaft In Cylinder Block
    G01593137Courtesy of FORD MOTOR CO.
    12. CAUTION: Fasteners No. 1, 5, 6, 7, 8 are studs. Fasteners No. 18-22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 2-4, 17 are M8 x 1.25 mm x 95.3 mm (0.05 in x 3.75 in) bolts. Fasteners. 9-16 are M10 x 1.5 mm x 106 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position or engine damage can result.
    Fig 14: Positioning Lower Cylinder Block And Installing Bolts And Studs
    G01593138Courtesy of FORD MOTOR CO.
  12. Position the lower cylinder block and install the bolts and studs.
    • Tighten the bolts and studs in the sequence shown in four stages.
    • Stage 1: Tighten fasteners 1-8 to 25 Nm (18 lb-ft).
    • Stage 2: Tighten fasteners 9-16 to 40 Nm (30 lb-ft).
    • Stage 3: Tighten fasteners 1-16 90 degrees.
    • Stage 4: Tighten fasteners 17-22 to 25 Nm (18 lb-ft).
  13. Using the special tool, measure crankshaft end play.
    Fig 15: Measuring Crankshaft End Play
    G01593139Courtesy of FORD MOTOR CO.
  14. Using the special tools, install the crankshaft rear oil seal.
    Fig 16: Installing Crankshaft Rear Oil Seal
    G01593140Courtesy of FORD MOTOR CO.
  15. Position the flexplate and install the bolts.
    Fig 17: Positioning Flexplate And Installing Bolts
    G01593141Courtesy of FORD MOTOR CO.
  16. Mount the engine on an engine stand.
    17. CAUTION: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
    NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
    NOTE: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.
    Fig 18: Installing Piston And Connecting Rod Assemblies
    G01593142Courtesy of FORD MOTOR CO.
  17. Using the special tools, install the piston and connecting rod assemblies.
  18. Install the connecting rod caps and bolts.
    • Tighten the bolts in two stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    Fig 19: Installing Connecting Rod Caps And Bolts
    G01593143Courtesy of FORD MOTOR CO.
  19. Fill the oil pump with clean engine oil. Rotate the oil pump one revolution. Drain the engine oil.
  20. Position the oil pump and install the bolts in the indicated sequence.
    Fig 20: Positioning Oil Pump And Installing Bolts
    G01593144Courtesy of FORD MOTOR CO.
  21. Position the oil pan baffle and install the nuts.
    • Tighten the nuts in two stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten 45 degrees.
    Fig 21: Positioning Oil Pan Baffle And Installing Nuts
    G01593145Courtesy of FORD MOTOR CO.
  22. Install a new O-ring seal on the oil pump screen and pick-up tube and lubricate with clean engine oil.
    Fig 22: Installing O-Ring Seal On Oil Pump Screen And Pick-Up Tube
    G01593146Courtesy of FORD MOTOR CO.
  23. Install the oil pump screen and pick-up tube.
    1. Position the oil pump screen and pick-up tube.
    2. Install the bolts.
    3. Install the nut.
    • Tighten the nut in two stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten 45 degrees.
    Fig 23: Installing Oil Pump Screen And Pick-Up Tube
    G01593147Courtesy of FORD MOTOR CO.
  24. Position the oil separator and the new gasket. Install the bolts.
    Fig 24: Positioning Oil Separator And New Gasket
    G01593148Courtesy of FORD MOTOR CO.
    25. NOTE: RH shown, LH similar.
    Fig 25: Installing Sequence Of Cylinder Head Bolts
    G01593149Courtesy of FORD MOTOR CO.
  25. Position the LH and RH cylinder heads and gaskets. Install the bolts.
    • Tighten the bolts in the sequence shown in six 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.
  26. Install the crankshaft damper bolt and rotate the crankshaft key way to the 11 o'clock position to locate top dead center (TDC).
    Fig 26: Installing Crankshaft Damper Bolt
    G01593150Courtesy of FORD MOTOR CO.
  27. Apply clean engine oil to the LH and RH camshaft followers.
    28. NOTE: RH shown, LH similar.
    Fig 27: Installing Camshaft Followers
    G01593151Courtesy of FORD MOTOR CO.
  28. Install the LH and RH camshaft followers.
  29. Apply engine oil to the LH and RH camshafts.
  30. Install the LH and RH camshafts.
    • Locate the camshafts as shown.
    Fig 28: Installing Camshafts
    G01593152Courtesy of FORD MOTOR CO.
  31. Position the RH camshaft caps and install the bolts in the sequence shown.
    Fig 29: Positioning RH Camshaft Caps And Installing Bolts
    G01593153Courtesy of FORD MOTOR CO.
  32. Position the LH camshaft caps and install the bolts in the sequence shown.
    Fig 30: Positioning LH Camshaft Caps And Installing Bolts
    G01593154Courtesy of FORD MOTOR CO.
    33. CAUTION: The camshaft bearing caps are positional and must be installed in their original locations and orientations or engine damage can occur.
    Fig 31: Verifying That Camshaft Bearing Caps Are In Correct Locations
    G01593155Courtesy of FORD MOTOR CO.
  33. Verify that the camshaft bearing caps are in the correct locations.
    34. NOTE: Clean and degrease the sealing surfaces with metal surface cleaner.
    Fig 32: Installing Camshaft Oil Seal Retainer
    G01593156Courtesy of FORD MOTOR CO.
  34. Install a new press-in-place gasket and install the camshaft oil seal retainer.
    35. NOTE: Lubricate the camshaft oil seal with clean engine oil.
    Fig 33: Installing Camshaft Oil Seal
    G01593157Courtesy of FORD MOTOR CO.
  35. Install a new camshaft oil seal.
    • Using the special tools positioned over the oil seal, turn to install the seal.
    36. CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 in) past flush of the end of the camshaft. The service pulley gets pressed on flush to the end of the camshaft.
    Fig 34: Installing Water Pump Drive Pulley
    G01593158Courtesy of FORD MOTOR CO.
  36. Using the special tool, install the water pump drive pulley.
  37. Remove the crankshaft damper bolt.
    Fig 35: Removing Crankshaft Damper Bolt
    G01593159Courtesy of FORD MOTOR CO.
  38. Install the crankshaft sprockets with the timing marks out.
    Fig 36: Installing Crankshaft Sprockets With Timing Marks Out
    G01593160Courtesy of FORD MOTOR CO.
    39. NOTE: LH shown, RH similar.
    Fig 37: Positioning Chain Tensioner In Soft Jawed Vise
    G01593161Courtesy of FORD MOTOR CO.
  39. Position the chain tensioner in a soft jawed vise.
    40. NOTE: LH shown, RH similar.
    Fig 38: Holding Chain Tensioner Ratchet Lock Mechanism Away From Ratchet Stem With Small Pick
    G01593162Courtesy of FORD MOTOR CO.
  40. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
    41. 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.
  41. Slowly compress the timing chain tensioner.
  42. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
    Fig 39: Installing Paper Clip Into Hole In Tensioner Housing
    G01593163Courtesy of FORD MOTOR CO.
  43. If the timing marks on the timing chains are not evident, use a permanent type marker to mark the crankshaft and camshaft timing marks on the LH and the RH timing chains.
    1. Mark any link to use as crankshaft timing mark.
    2. Starting with the crankshaft timing mark, count 29 links and mark the link as the exhaust cam sprocket timing mark.
    3. Continue counting to link 42. Mark the link as the intake sprocket timing mark.
    Fig 40: Locating Timing Marks On Timing Chain
    G01593164Courtesy of FORD MOTOR CO.
  44. Position the LH timing chain and guide and install the bolts.
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
    Fig 41: Positioning LH Timing Chain And Guide And Installing Bolts
    G01593165Courtesy of FORD MOTOR CO.
  45. Install the LH timing chain tensioner and the tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
    Fig 42: Installing LH Timing Chain Tensioner And Tensioner Arm
    G01593166Courtesy of FORD MOTOR CO.
  46. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
    Fig 43: Installing Crankshaft Damper Bolt
    G01593167Courtesy of FORD MOTOR CO.
  47. Verify that the RH camshafts are correctly positioned.
    Fig 44: Verifying RH Camshafts Are Correctly Positioned
    G01593168Courtesy of FORD MOTOR CO.
  48. Install the RH timing chain and chain guide and install the bolts.
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
    Fig 45: Installing RH Timing Chain And Chain Guide And Installing Bolts
    G01593169Courtesy of FORD MOTOR CO.
  49. Install the RH timing chain tensioner and tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
    Fig 46: Installing RH Timing Chain Tensioner And Tensioner Arm
    G01593170Courtesy of FORD MOTOR CO.
  50. Remove the LH and RH timing chain tensioner piston retaining wires.
  51. Rotate crankshaft counterclockwise 120 degrees to top dead center (TDC).
  52. 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 47: Verifying Timing
    G01593171Courtesy of FORD MOTOR CO.
  53. Remove the crankshaft damper bolt.
    Fig 48: Removing Crankshaft Damper Bolt
    G01593172Courtesy of FORD MOTOR CO.
    54. CAUTION: The pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 30 or 30RFF only.
    Fig 49: Installing Ignition Pulse Wheel
    G01593173Courtesy of FORD MOTOR CO.
  54. Install the ignition pulse wheel.
  55. Install the LH and RH spark plugs.
    Fig 50: Installing Spark Plugs
    G01593174Courtesy of FORD MOTOR CO.
  56. Install the special tool to hold the flexplate.
    Fig 51: Installing Special Tool To Hold Flexplate
    G01593175Courtesy of FORD MOTOR CO.
  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.
    Fig 52: Identifying Locations For Applying Gasket And Sealant
    G01593176Courtesy of FORD MOTOR CO.
  58. Apply a 6 mm (0.24 in) dot of gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
    59. NOTE: Fasteners No. 1 and 6 are studs.
    Fig 53: Positioning Front Cover And Installing Bolts And Studs
    G01593177Courtesy of FORD MOTOR CO.
  59. 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.
    Fig 54: Installing Crankshaft Front Oil Seal
    G01593178Courtesy of FORD MOTOR CO.
  60. Using the special tool, install the crankshaft front oil seal.
    61. NOTE: Inspect and replace the O-rings as needed.
    NOTE: Apply clean engine oil to aid in installing.
    Fig 55: Installing Coolant Tube, Bolt And Stud
    G01593179Courtesy of FORD MOTOR CO.
  61. Install the coolant tube, the bolt and the stud.
  62. Install the oil pressure sensor.
    Fig 56: Installing Oil Pressure Sensor
    G01593180Courtesy of FORD MOTOR CO.
  63. Install a new seal on the oil level indicator tube and apply clean engine oil.
    Fig 57: Installing Seal On Oil Level Indicator Tube
    G01593181Courtesy of FORD MOTOR CO.
  64. Install the oil level indicator tube and install the bolt.
    Fig 58: Installing Oil Level Indicator Tube And Installing Bolt
    G01593182Courtesy of FORD MOTOR CO.
  65. Apply clean engine oil to the oil filter O-ring and install a new oil filter.
    Fig 59: Installing Oil Filter
    G01593183Courtesy of FORD MOTOR CO.
    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.
    Fig 60: Applying Gasket And Sealant To End Of Crankshaft Damper Keyway Slot
    G01593184Courtesy of FORD MOTOR CO.
  66. Apply gasket and sealant to the end of the crankshaft damper keyway slot.
  67. Using the special tool, install the crankshaft vibration damper.
    Fig 61: Installing Crankshaft Vibration Damper
    G01593185Courtesy of FORD MOTOR CO.
  68. Install the crankshaft vibration damper washer and bolt.
    • Tighten the bolt in four 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 62: Installing Crankshaft Vibration Damper Washer And Bolt
    G01593186Courtesy of FORD MOTOR CO.
    69. NOTE: Clean the valve cover sealing area using metal surface cleaner before installing a new gasket.
  69. Install new gaskets in the valve covers.
    70. 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.
    Fig 63: Identifying Locations For Applying Gasket And Sealant
    G01593187Courtesy of FORD MOTOR CO.
  70. Apply a 8 mm (0.31 in) dot of gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
    71. NOTE: Fasteners No. 2,3 and 5,9 are studs.
    Fig 64: Positioning RH Valve Cover And Installing Bolts And Studs
    G01593188Courtesy of FORD MOTOR CO.
  71. Position the RH valve cover and install the bolts and studs in the sequence shown.
    72. NOTE: Fasteners No.1, 3, 5-8, and 11 are studs.
    Fig 65: Positioning LH Valve Cover And Installing Bolts And Studs
    G01593189Courtesy of FORD MOTOR CO.
  72. Position the LH valve cover and install the bolts and studs in the sequence shown.
  73. Install the water pump.
    • Position the water pump and install the mounting bolts.
    • Tighten the bolts in two stages.
    • Step 1: Tighten to 10 Nm (89 lb-in).
    • Step 2: Tighten an additional 90 degrees.
    Fig 66: Installing Water Pump
    G01593190Courtesy of FORD MOTOR CO.
  74. Install the heater hose assembly and connect the heater hose to the water pump.
    Fig 67: Installing Heater Hose Assembly And Connecting Heater Hose To Water Pump
    G01593191Courtesy of FORD MOTOR CO.
  75. Install the coolant tube assembly and connect the two hose clamps.
    Fig 68: Installing Coolant Tube Assembly And Connecting Hose Clamps
    G01593192Courtesy of FORD MOTOR CO.
  76. Connect the heater hose and the water temperature electrical connectors to the coolant crossover tube.
    Fig 69: Connecting Heater Hose And Water Temperature Electrical Connectors To Coolant Crossover Tube
    G01593193Courtesy of FORD MOTOR CO.
  77. Rotate the drive belt tensioner clockwise and install the water pump belt.
    Fig 70: Installing Water Pump Belt
    G01593194Courtesy of FORD MOTOR CO.
  78. Install the water pump drive belt cover and nuts.
    Fig 71: Installing Water Pump Drive Belt Cover And Nuts
    G01593195Courtesy of FORD MOTOR CO.
  79. Connect the water pump outlet hose.
    Fig 72: Connecting Water Pump Outlet Hose
    G01593196Courtesy of FORD MOTOR CO.
  80. Position the evaporative emissions (EVAP) tube and install the nuts.
    Fig 73: Positioning Evaporative Emissions Tube And Installing Nuts
    G01593197Courtesy of FORD MOTOR CO.
  81. Position the RH exhaust manifold and gasket and install the nuts in the sequence shown.
    Fig 74: Positioning RH Exhaust Manifold And Gasket And Installing Nuts
    G01593198Courtesy of FORD MOTOR CO.
  82. Position the LH exhaust manifold and gasket and install the nuts in the sequence shown.
    Fig 75: Positioning LH Exhaust Manifold And Gasket And Installing Nuts
    G01593199Courtesy of FORD MOTOR CO.
  83. Position the fuel charging harness and install the nut.
    Fig 76: Positioning Fuel Charging Harness And Installing Nut
    G01593200Courtesy of FORD MOTOR CO.
    84. NOTE: Clean and inspect the sealing surfaces before installing the gaskets.
  84. Install new gaskets in the lower intake manifold.
  85. Position the lower intake manifold and install the bolts in the sequence shown.
    Fig 77: Positioning Lower Intake Manifold And Installing Bolts
    G01593201Courtesy of FORD MOTOR CO.
  86. Connect the fuel injector electrical connectors.
    Fig 78: Connecting Fuel Injector Electrical Connectors
    G01593202Courtesy of FORD MOTOR CO.
  87. Install the ignition coil, the stud and the nuts.
    Fig 79: Installing Ignition Coil, Stud And Nuts
    G01593203Courtesy of FORD MOTOR CO.
  88. Install the ground strap and the nut to the ignition coil stud.
    Fig 80: Installing Ground Strap And Nut To Ignition Coil Stud
    G01593204Courtesy of FORD MOTOR CO.
    89. NOTE: LH shown, RH similar.
    NOTE: Apply a film of caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.
    Fig 81: Connecting Spark Plug Wires
    G01593205Courtesy of FORD MOTOR CO.
  89. Connect the LH and RH spark plug wires.
  90. Connect the LH HO2S electrical connector.
    Fig 82: Connecting LH HO2S Electrical Connector
    G01593206Courtesy of FORD MOTOR CO.
  91. Position the knock sensor (KS) and install the bolt.
    Fig 83: Positioning Knock Sensor And Installing Bolt
    G01593207Courtesy of FORD MOTOR CO.
  92. Connect the RH radio ignition interference capacitor, ignition coil electrical connector and HO2S electrical connectors. Clip the HO2S connectors into place.
    Fig 84: Connecting RH Radio Ignition Interference Capacitor, Ignition Coil And HO2S Electrical Connectors
    G01593208Courtesy of FORD MOTOR CO.
  93. Install new gaskets in the upper intake manifold, if required.
  94. Position the upper intake manifold and install the bolts in the sequence shown.
    Fig 85: Positioning Upper Intake Manifold And Installing Bolts
    G01593209Courtesy of FORD MOTOR CO.
  95. Connect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector.
    Fig 86: Connecting Exhaust Gas Recirculation Vacuum Regulator Solenoid Electrical Connector
    G01593210Courtesy of FORD MOTOR CO.
  96. Connect the positive crankcase ventilation (PCV) and evaporative (EVAP) emissions hoses from the upper intake manifold.
    Fig 87: Connecting Positive Crankcase Ventilation And Evaporative Emissions Hoses
    G01593211Courtesy of FORD MOTOR CO.
  97. Connect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
    Fig 88: Connecting Throttle Position Sensor And Idle Air Control Valve Electrical Connectors
    G01593212Courtesy of FORD MOTOR CO.
  98. Connect the exhaust gas recirculation (EGR) tube to the exhaust manifold.
    Fig 89: Connecting Exhaust Gas Recirculation Tube To Exhaust Manifold
    G01593213Courtesy of FORD MOTOR CO.
  99. Connect the differential pressure feedback EGR system electrical connector.
    Fig 90: Connecting Differential Pressure Feedback EGR System Electrical Connector
    G01593214Courtesy of FORD MOTOR CO.
  100. Install the crankshaft position (CKP) sensor.
    1. Install the sensor.
    2. Install the bolt.
    3. Connect the electrical connector and clip into place.
    Fig 91: Installing Crankshaft Position Sensor
    G01593215Courtesy of FORD MOTOR CO.
    101. NOTE: The pulley has LH threads.
    Fig 92: Installing Crankshaft Pulley
    G01593216Courtesy of FORD MOTOR CO.
  101. Install the crankshaft pulley.
  102. Remove the special tool.
    Fig 93: Removing Special Tool
    G01593217Courtesy of FORD MOTOR CO.
  103. Connect the oil pressure sensor.
    Fig 94: Connecting Oil Pressure Sensor
    G01593218Courtesy of FORD MOTOR CO.
  104. Connect the harness to the front LH valve cover studs.
    Fig 95: Connecting Harness To Front LH Valve Cover Studs
    G01593219Courtesy of FORD MOTOR CO.
  105. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 96: Connecting Camshaft Position Sensor Electrical Connector
    G01593220Courtesy of FORD MOTOR CO.
  106. 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 lb-ft).
    • Stage 2: Tighten bolts 1 through 4 an additional 90 degrees.
    Fig 97: Positioning A/C Compressor Bracket And Installing Bolts
    G01593221Courtesy of FORD MOTOR CO.
  107. Position the A/C compressor and install the bolts.
    Fig 98: Positioning A/C Compressor And Installing Bolts
    G01593222Courtesy of FORD MOTOR CO.
  108. 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.
    Fig 99: Connecting A/C Compressor
    G01593223Courtesy of FORD MOTOR CO.
  109. Position the power steering pump and install the bolts.
    Fig 100: Positioning Power Steering Pump And Installing Bolts
    G01593224Courtesy of FORD MOTOR CO.
  110. Install the generator.
    1. Position the generator.
    2. Install the studs.
    3. Install the bolt.
    4. Connect the electrical connector.
    Fig 101: Installing Generator
    G01593225Courtesy of FORD MOTOR CO.
  111. Install the accessory drive belt.
    112. NOTE: For out of vehicle repair the transaxle must be installed before the oil pan.
  112. Remove the engine from the stand.
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