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Home >> Ford >> 2005 >> Escape Base, 3.0 1, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine - 2.3L - (Except Hybrid)) >> Assembly >> Engine (Except Block)

Engine (Except Block)

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL DESCRIPTION

G03898823
 Heavy Duty Floor Crane 014-00071 or equivalent
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G03898747
 Alignment Plate, Camshaft 303 - 465 (T94P-6256-CH)
G03897953
 Timing Peg, Crankshaft 303 - 507
G03898935
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
G03898936
 Adapter for 205-126 (205-072-02)
G03950442
 Installer, Front Oil Seal 303-096 (T74P-6150-A)
G03898710
 Installer, Crankshaft Rear Main Oil Seal 303 - 328 (T88P-6701-B1)
G03973228
 Aligner, Clutch Disc 308-006 (T71P-7137-H)
MATERIAL SPECIFICATIONS

Item Specification
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) 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: Exploded View Of Lower Engine Block
G03898050Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Front Engine Block
G03898051Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Cylinder Head
G03898052Courtesy of FORD MOTOR CO.
Fig 4: Exploded View Of Intake Manifold
G03898053Courtesy of FORD MOTOR CO.
CAUTION: 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.
CAUTION: 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. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

    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: Installing Special Tool
    G03897737Courtesy of FORD MOTOR CO.
  3. Install the special tool.
  4. If removed, install the halfshaft support bracket and bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 7: Installing Halfshaft Support Bracket And Bolts
      G03898029Courtesy 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 Nm (89 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
      Fig 8: Identifying Tightening Sequence Of Oil Pump Assembly Bolts
      G03898057Courtesy of FORD MOTOR CO.
  6. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 Nm (89 lb-in).
      Fig 9: Installing Oil Pump Pickup Tube Gasket And Pickup Tube
      G03898027Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the crankshaft rear main oil seal.
    Fig 10: Installing Crankshaft Rear Main Oil Seal
    G03897721Courtesy of FORD MOTOR CO.
  8. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
    • To install, tighten to 10 Nm (89 lb-in).
      Fig 11: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
      G03897722Courtesy 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.
    NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    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. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 13: Identifying Tightening Sequence Of Oil Pan Bolts
      G03897725Courtesy of FORD MOTOR CO.
  12. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 14: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
    13. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    CAUTION: 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.
  13. 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.
  14. Apply silicone gasket and sealant to the locations shown.
    Fig 15: Identifying Silicone Gasket And Sealant Application Points
    G03897827Courtesy of FORD MOTOR CO.
  15. Install a new head gasket.
    Fig 16: Installing Head Gasket
    G03898065Courtesy of FORD MOTOR CO.
    16. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    NOTE: Lubricate the bolts with clean engine oil prior to installation.
  16. Install new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 15 Nm (11 lb-ft).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
      Fig 17: Identifying Tightening Sequence Cylinder Head Bolts
      G03897828Courtesy of FORD MOTOR CO.
    17. 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.
  17. 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 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (12 lb-ft).
      Fig 18: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts
      G03898067Courtesy of FORD MOTOR CO.
    18. NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
  18. 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 19: Installing Crankshaft Sprocket Diamond Washer On Both Sides Of Crankshaft Sprocket
      G03898068Courtesy of FORD MOTOR CO.
  19. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 20: Identifying Oil Pump Chain, Sprocket And Bolt
      G03898069Courtesy of FORD MOTOR CO.
  20. Install the oil pump chain guide and the shoulder bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 21: Identifying Oil Pump Chain Guide And Shoulder Bolts
      G03898070Courtesy of FORD MOTOR CO.
  21. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 22: Installing Oil Pump Chain Tensioner
      G03898071Courtesy of FORD MOTOR CO.
    22. CAUTION: The special tool 303 - 465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    Fig 23: Identifying Special Tool
    G03898006Courtesy of FORD MOTOR CO.
  22. Install the special tool in the slots on the rear of both camshafts.
  23. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    Fig 24: Installing Camshaft Drive Gears Bolts
    G03897782Courtesy of FORD MOTOR CO.
  24. Install the LH timing chain guide and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 25: Identifying LH Timing Chain Guide And Bolts
      G03897780Courtesy of FORD MOTOR CO.
  25. Install the timing chain.
    Fig 26: Identifying Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  26. Install the RH timing chain guide.
    Fig 27: Identifying Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
    27. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    Fig 28: Compressing Timing Chain Tensioner Plunger
    G03898077Courtesy of FORD MOTOR CO.
  27. Using the edge of a vise, compress the timing chain tensioner plunger.
  28. Using a small pick, push back and hold the ratchet mechanism.
    Fig 29: Pushing Back And Hold Ratchet Mechanism
    G03898078Courtesy of FORD MOTOR CO.
  29. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 30: Pushing Ratchet Arm Back Into Tensioner Housing
    G03898079Courtesy of FORD MOTOR CO.
  30. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 31: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet Assembly
    G03898080Courtesy of FORD MOTOR CO.
  31. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
      Fig 32: Identifying Timing Chain Tensioner Bolts
      G03897786Courtesy of FORD MOTOR CO.
    32. CAUTION: The special tool 303 - 465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  32. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • To install, tighten to 65 Nm (48 lb-ft).
      Fig 33: Installing Camshaft Drive Gears Bolts
      G03897782Courtesy of FORD MOTOR CO.
    33. 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.
  33. Clean and inspect the mounting surfaces of the engine and the front cover.
    34. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    Fig 34: Applying Silicone Gasket And Sealant On Engine Front Cover
    G03897744Courtesy of FORD MOTOR CO.
  34. 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.
  35. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
    • Tighten the 8-mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
      Fig 35: Identifying Tightening Sequence Of Engine Front Cover
      G03897745Courtesy of FORD MOTOR CO.
    36. NOTE: Remove the through-bolt from the special tool.
    NOTE: Lubricate the oil seal with clean engine oil.
    Fig 36: Installing Crankshaft Front Oil Seal Using Special Tool
    G03897717Courtesy of FORD MOTOR CO.
  36. Using the special tool, install a new crankshaft front oil seal.
    37. NOTE: Do not reuse the crankshaft damper bolt.
    NOTE: Apply clean engine oil on the seal area before installing.
  37. Install the crankshaft pulley and hand-tighten the bolt.
    38. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
  38. 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.
    • Rotate the pulley as necessary to align the bolt holes.
      Fig 37: Aligning Crankshaft Pulley Hole With Engine Front Cover Holes
      G03898086Courtesy of FORD MOTOR CO.
    39. CAUTION: Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
  39. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
      Fig 38: Tightening Crankshaft Pulley Bolt
      G03898087Courtesy of FORD MOTOR CO.
  40. Remove the 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt.
    Fig 39: Aligning Crankshaft Pulley Hole With Engine Front Cover Holes
    G03898086Courtesy of FORD MOTOR CO.
  41. Remove the special tool.
    Fig 40: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  42. Remove the special tool.
    Fig 41: Identifying Special Tool
    G03898006Courtesy of FORD MOTOR CO.
    43. NOTE: Only turn the engine in the normal direction of rotation.
  43. Turn the engine 2 complete revolutions.
    44. NOTE: Only turn the engine in the normal direction of rotation.
  44. Turn the crankshaft until the No. 1 piston is at top dead center (TDC).
  45. Install the special tool.
    Fig 42: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
    46. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
  46. 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, correct the engine timing.
      Fig 43: Aligning Crankshaft Pulley Hole With Engine Front Cover Holes
      G03898086Courtesy of FORD MOTOR CO.
  47. Using the special tool, check the position of the camshafts.
    • If it is not possible to install the special tool, correct the engine timing.
      Fig 44: Identifying Special Tool
      G03898006Courtesy of FORD MOTOR CO.
    48. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment jig supplied with the new part.
  48. Install a new CKP sensor.
    • Do not tighten the bolts at this time.
      Fig 45: Installing CKP Sensor
      G03898012Courtesy of FORD MOTOR CO.
  49. Adjust the CKP sensor alignment jig and tighten the bolts.
    • Tighten to 7 Nm (62 lb-in).
      Fig 46: Locating CKP Sensor Adjusting Bolts
      G03897758Courtesy of FORD MOTOR CO.
  50. Remove the 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt.
    Fig 47: Aligning Crankshaft Pulley Hole With Engine Front Cover Holes
    G03898086Courtesy of FORD MOTOR CO.
  51. Install the engine plug bolt.
    Fig 48: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    52. 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.
  52. Clean the valve cover gasket surface with metal surface cleaner.
  53. Apply silicone gasket and sealant to the locations shown.
    Fig 49: Identifying Locations For Applying Silicone Gasket And Sealant
    G03898098Courtesy of FORD MOTOR CO.
    54. 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.
  54. Install the valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
      Fig 50: Identifying Tightening Sequence Of Valve Cover
      G03897691Courtesy of FORD MOTOR CO.
  55. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
    • Tighten the CHT sensor to 12 Nm (9 lb-ft).
    • Tighten the spark plugs to 15 Nm (11 lb-ft).
      Fig 51: Installing Cylinder Head Temperature Sensor And Spark Plugs
      G03898004Courtesy of FORD MOTOR CO.
    56. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
  56. Install the coil-on-plugs, bolts and the crankcase vent tube.
    • Tighten to 10 Nm (89 lb-in).
      Fig 52: Installing Coil-On-Plugs, Bolts And Crankcase Vent Tube
      G03898003Courtesy of FORD MOTOR CO.
  57. If equipped, install the block heater.
    • Tighten to 21 Nm (15 lb-ft).
      Fig 53: Identifying Block Heater
      G03898002Courtesy of FORD MOTOR CO.
    58. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
  58. Install the crankcase vent oil separator and the KS.
    • Tighten the oil separator bolts to 10 Nm (89 lb-in).
    • Tighten the KS to 20 Nm (15 lb-ft).
      Fig 54: Installing Crankcase Vent Oil Separator And KS
      G03898103Courtesy of FORD MOTOR CO.
  59. Install the coolant hoses.
    Fig 55: Installing Coolant Hoses
    G03897999Courtesy of FORD MOTOR CO.
  60. Install the coolant hose.
    Fig 56: Installing Coolant Hose
    G03897998Courtesy of FORD MOTOR CO.
  61. Install the coolant hose.
    Fig 57: Installing Coolant Hose
    G03897997Courtesy of FORD MOTOR CO.
  62. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
    Fig 58: Connecting CHT Sensor
    G03897996Courtesy of FORD MOTOR CO.
  63. Attach the wiring harness retainer.
    Fig 59: Attaching Wiring Harness Retainer
    G03897995Courtesy of FORD MOTOR CO.
  64. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 60: Connecting Coil-On-Plug And Camshaft Position Sensor Electrical Connectors
    G03897994Courtesy of FORD MOTOR CO.
  65. Connect the exhaust gas recirculation (EGR) valve and radio interference capacitor electrical connectors. Attach the wiring harness retainer.
    Fig 61: Connecting Exhaust Gas Recirculation Valve And Radio Interference Capacitor Electrical Connectors
    G03897993Courtesy of FORD MOTOR CO.
  66. Attach the wiring harness retainer.
    Fig 62: Attaching Wiring Harness Retainer
    G03897992Courtesy of FORD MOTOR CO.
    67. 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.
  67. 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 63: Locating O-Ring Seals
      G03885875Courtesy of FORD MOTOR CO.
  68. Position the fuel rail spacers.
    Fig 64: Identifying Fuel Rail Spacers
    G03897991Courtesy of FORD MOTOR CO.
  69. Install the fuel rail with the fuel injectors and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 65: Installing Fuel Rail With Fuel Injectors And Bolts
      G03897990Courtesy of FORD MOTOR CO.
  70. Connect the 4 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
    Fig 66: Connecting Fuel Injector Electrical Connectors
    G03897989Courtesy of FORD MOTOR CO.
  71. Install the EGR tube.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 67: Installing EGR Tube
      G03897988Courtesy of FORD MOTOR CO.
  72. Position the intake manifold and connect the positive crankcase ventilation hose.
    Fig 68: Connecting Positive Crankcase Ventilation Hose
    G03897987Courtesy of FORD MOTOR CO.
    73. NOTE: Inspect and install new intake manifold gaskets, if necessary.
  73. Install the intake manifold gaskets and intake manifold.
    • Tighten the bolts to 18 Nm (13 lb-ft).
      Fig 69: Installing Intake Manifold Gaskets And Intake Manifold
      G03897986Courtesy of FORD MOTOR CO.
  74. Connect the throttle position (TP) sensor electrical connector.
    Fig 70: Connecting Throttle Position Sensor Electrical Connector
    G03897985Courtesy of FORD MOTOR CO.
  75. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    Fig 71: Connecting Fuel Rail Pressure And Temperature Sensor Electrical Connector And Vacuum Tube
    G03897984Courtesy of FORD MOTOR CO.
  76. Connect the swirl control valve electrical connector.
    Fig 72: Connecting Swirl Control Valve Electrical Connector
    G03897983Courtesy of FORD MOTOR CO.
  77. Connect the idle air control (IAC) motor electrical connector.
    Fig 73: Connecting Idle Air Control Motor Electrical Connector
    G03897982Courtesy of FORD MOTOR CO.
  78. Connect the temperature manifold absolute pressure (TMAP) electrical connector.
    Fig 74: Connecting Temperature Manifold Absolute Pressure Electrical Connector
    G03897981Courtesy of FORD MOTOR CO.
  79. Connect the KS and attach the 2 wiring harness retainers.
    Fig 75: Connecting KS And Attach Wiring Harness Retainers
    G03897980Courtesy of FORD MOTOR CO.
  80. Attach the 2 wiring harness retainers.
    Fig 76: Attaching Wiring Harness Retainers
    G03897979Courtesy of FORD MOTOR CO.
  81. If removed, install the capacitor and bolt.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 77: Installing Capacitor And Bolt
      G03897978Courtesy of FORD MOTOR CO.
    82. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
  82. 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 Nm (25 lb-ft).
    • Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
    83. NOTE: Clean the gasket mating surfaces with metal surface cleaner.
  83. Install the oil filter adapter with a new gasket and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 78: Installing Oil Filter Adapter With Gasket And Bolts
      G03897977Courtesy of FORD MOTOR CO.
  84. Connect the oil pressure sensor electrical connector.
    Fig 79: Connecting Oil Pressure Sensor Electrical Connector
    G03897976Courtesy of FORD MOTOR CO.
    85. NOTE: Install a new O-ring seal on the oil level indicator tube and lubricate with clean engine oil prior to installing.
  85. Install the oil level indicator and bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 80: Installing Oil Level Indicator And Bolts
      G03897975Courtesy of FORD MOTOR CO.
    86. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.
  86. Install the thermostat housing and bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 81: Installing Thermostat Housing And Bolts
      G03897974Courtesy of FORD MOTOR CO.
  87. Connect the oil cooler hoses.
    Fig 82: Connecting Oil Cooler Hoses
    G03897973Courtesy of FORD MOTOR CO.
  88. Attach the 2 wiring harness retainers.
    Fig 83: Attaching Wiring Harness Retainers
    G03897972Courtesy of FORD MOTOR CO.
  89. Install the engine vacuum tube.
    • Connect the engine vacuum tube.
    • Attach the 2 engine vacuum tube retainers.
      Fig 84: Installing Engine Vacuum Tube
      G03897971Courtesy of FORD MOTOR CO.
    90. NOTE: Clean the coolant pump mating surface with metal surface cleaner.
    NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
  90. Install the coolant pump and bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 85: Installing Coolant Pump And Bolts
      G03897970Courtesy of FORD MOTOR CO.
  91. Install the coolant pump pulley and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 86: Installing Coolant Pump Pulley And Bolts
      G03897969Courtesy of FORD MOTOR CO.
  92. If equipped, install the accessory drive belt idler pulley.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 87: Installing Accessory Drive Belt Idler Pulley
      G03897968Courtesy of FORD MOTOR CO.
  93. Install the accessory drive belt idler pulley.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 88: Installing Accessory Drive Belt Idler Pulley
      G03897967Courtesy of FORD MOTOR CO.
  94. Install the generator and bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 89: Installing Generator And Bolts
      G03897966Courtesy of FORD MOTOR CO.
  95. Position a new exhaust manifold gasket on the engine.
    96. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
    CAUTION: 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.
  96. Position the catalytic converter and tighten the 7 exhaust manifold nuts in the sequence shown.
    • Stage 1: Tighten to 47 Nm (35 lb-ft).
    • Stage 2: Tighten to 47 Nm (35 lb-ft).
      Fig 90: Identifying Tightening Sequence Of Exhaust Manifold Nuts
      G03898139Courtesy of FORD MOTOR CO.
  97. Install the heat shield and the 6 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 91: Installing Heat Shield And Bolts
      G03897964Courtesy of FORD MOTOR CO.
  98. Install the 2 catalytic converter bracket bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 92: Installing Catalytic Converter Bracket Bolts
      G03897963Courtesy of FORD MOTOR CO.
  99. Connect the generator electrical connections and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 93: Connecting Generator Electrical Connections
      G03897962Courtesy of FORD MOTOR CO.
  100. Connect the CKP sensor electrical connector.
    Fig 94: Connecting CKP Sensor Electrical Connector
    G03897961Courtesy of FORD MOTOR CO.
  101. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.

    102. Vehicles with automatic transaxle 

  102. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in 3 stages:
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Tighten to 80 Nm (50 lb-ft).
    • Stage 3: Tighten to 112 Nm (83 lb-ft).
      Fig 95: Identifying Tightening Sequence Of Flexplate Bolts
      G03898144Courtesy of FORD MOTOR CO.

    103. Vehicles with manual transaxle 

  103. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in 3 stages:
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Tighten to 80 Nm (50 lb-ft).
    • Stage 3: Tighten to 112 Nm (83 lb-ft).
      Fig 96: Identifying Tightening Sequence Of Flywheel Bolts
      G03897718Courtesy of FORD MOTOR CO.
  104. Install the starter motor isolator.
    Fig 97: Installing Starter Motor Isolator
    G03897958Courtesy of FORD MOTOR CO.
  105. Lubricate the transaxle input shaft pilot bearing with front axle grease.
    Fig 98: Lubricating Transaxle Input Shaft Pilot Bearing With Front Axle Grease
    G03975684Courtesy of FORD MOTOR CO.
  106. Using the special tool, position the clutch disc on the flywheel.
    Fig 99: Positioning Clutch Disc On Flywheel
    G03898148Courtesy of FORD MOTOR CO.
    107. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
  107. Position the clutch pressure plate and install the bolts.
    • Tighten to 27 Nm (20 lb-ft) in a star pattern sequence.
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