All vehicles
WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
- Install the crankshaft upper main bearings.
- Install the crankshaft.
- Install the crankshaft rear oil seal.
- Apply 2 dots of gasket maker between the rear bearing cap and the cylinder block.
- Install the crankshaft lower main bearings.
- Install the main bearing caps.
- Wedge a large screwdriver at the location shown to hold the crankshaft forward until all the bolts are tightened.
- Install the bolts and tighten in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
- For crankshaft and crankshaft bearing component tests, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- If removed, install the camshaft bearings.
- Use the Camshaft Service Set.
- Install the camshaft.
- Install the camshaft retainer.
- Tighten to 10 Nm (89 lb-in).
- Inspect the camshaft end play. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Align the timing marks.
- Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
- Install the bolt.
- Tighten to 63 Nm (46 lb-ft).
- Install the piston and connecting rod assemblies.
- Use a piston ring compressor.
- Install the connecting rod bearings.
- Install the connecting rod caps and nuts.
- Tighten to 35 Nm (26 lb-ft).
- Install the oil pan baffle and nuts.
- Tighten to 32 Nm (24 lb-ft).
- Install the oil pump and bolt.
- Tighten to 48 Nm (35 lb-ft).
- Install the hydraulic lash adjusters.
- Install the hydraulic lash adjuster guide plates.
- Install the hydraulic lash adjuster guide plate retainer.
- Tighten to 12 Nm (9 lb-ft).
- Install new head gaskets.
- Install the cylinder heads.
- Install the bolts. Tighten the bolts in the sequence shown in 5 stages.
- Stage 1: Tighten to 50 N.m (37 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 30 N.m (22 lb-ft).
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten an additional 90 degrees.
- Install a new oil filter.
- Install the oil level indicator and tube assembly.
- Coat the oil level indicator tube with silicone gasket and sealant.
- Align the timing marks.
- Install a new engine front cover gasket and the engine front cover.
- Apply thread sealant with PTFE on the bolts to be installed in the locations shown.
- Install the 10 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Install the knock sensor (KS) and bolt.
- Tighten to 25 Nm (18 lb-ft).
- Install the crankshaft position (CKP) sensor and bolts.
- Tighten to 10 Nm (89 lb-in).
- 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.
- Position a new oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with the gasket clips.
- Install the oil pan and bolts. Tighten in the sequence shown.
- Tighten to 12 Nm (9 lb-ft).
- Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Position a new exhaust manifold gasket and the LH exhaust manifold. Install new bolts and stud bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 23 Nm (17 lb-ft).
- Position the exhaust manifold-to-EGR valve tube. Finger tighten the fitting.
- Position a new exhaust manifold gasket and the RH exhaust manifold and install new bolts and stud bolts. Tighten the bolts and stud bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 23 Nm (17 lb-ft).
- Position the RH engine support insulator bracket and install the bolts.
- Tighten to 48 Nm (35 lb-ft).
- Position the LH engine support insulator bracket and install the bolt and the stud bolts.
- Tighten to 48 Nm (35 lb-ft).
- Position the starter splash shield and install the bolt and the nut.
- Tighten to 10 Nm (89 lb-in).
- Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
- Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment gauge is 38 degrees from the centerline of the engine.
- Install the camshaft synchronizer retaining bolt.
- Tighten to 30 Nm (22 lb-ft).
- Install the camshaft position (CMP) sensor.
- Tighten to 3 Nm (27 lb-in).
- Apply 4 beads of silicone gasket and sealant.
- Install new intake manifold gaskets and end seals.
- Position the intake manifold gaskets.
- Position the end seals.
- Install the lower intake manifold and bolts. Tighten in sequence shown.
- Tighten to 29 Nm (21 lb-ft).
- Position the fuel rail and fuel injectors and install the bolts.
- Install the push rods and the rocker arms.
- Install the push rods.
- Install the rocker arms and bolts.
- Tighten to 32 Nm (24 lb-ft).
- Apply a bead of silicone gasket and sealant to the 4 intake-to-cylinder head seams.
- Install new valve cover gaskets.
- Install the valve covers and bolts. Tighten in the sequence shown.
- Tighten to 12 Nm (9 lb-ft).
- Using the special tool, install the crankshaft damper.
- Install the bolt.
- Tighten to 145 Nm (107 lb-ft).
- Install the crankshaft pulley and the 4 bolts.
- Tighten to 63 Nm (46 lb-ft).
- Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Install the generator mounting bracket and the bolts.
- Tighten to 47 Nm (35 lb-ft).
- Position the ignition coil assembly and install the bolts.
- Tighten to 6 Nm (53 lb-in).
- Position the RH engine lifting eye and install the nuts.
- Tighten to 20 Nm (15 lb-ft).
- Position the LH engine lifting eye and install the nuts.
- Tighten to 20 Nm (15 lb-ft).
- Position the engine ground strap and install the bolt.
- Tighten to 10 Nm (89 lb-in).
- Install the spark plug wires. For additional information, refer to ENGINE IGNITION - 3.0L (2V) article.
- Position the wiring harness and attach the wiring harness retainers to the valve cover studs. Connect the fuel injector, engine coolant temperature (ECT) sensor and ignition coil electrical connectors.
- Connect the positive crankcase ventilation (PCV) valve and differential pressure feedback EGR sensor electrical connectors. Attach the wiring harness retainer to the differential pressure feedback EGR sensor.
- Connect the camshaft position sensor, the oil pressure switch, and, if the vehicle is equipped with a manual transmission, the knock sensor electrical connectors. Attach the wiring harness and electrical connector retainers.
- Attach the wiring harness retainer to the generator.
- Attach the wiring harness retainer and connect the crankshaft position (CKP) sensor electrical connector.
- Install the Lifting Eyes and the lifting equipment.
- Remove the engine from work stand.
- Install the engine-to-transmission spacer plate.
- Install the flywheel or flexplate.
- Tighten to 80 Nm (59 lb-ft).
NOTE:
Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
NOTE:
Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with clean engine oil.
NOTE:
Lubricate the camshaft and the camshaft bearings with clean engine oil.
NOTE:
Lubricate the piston and connecting rod assemblies with clean engine oil.
NOTE:
Lubricate the connecting rod bearings with clean engine oil.
NOTE:
Lubricate the hydraulic lash adjusters with clean engine oil.
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 or 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.
NOTE:
The end of the oil level tube should be cleaned with metal surface prep before application of the sealant.
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.
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 all traces of old sealant.
CAUTION:
The thickness of the sealant must be between 4-6 mm (0.16-0.23 inch) or oil leaks could occur.
NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. 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:
Make sure the fasteners are clean and dry prior to installation.
NOTE:
Do not tighten the exhaust manifold-to-exhaust gas recirculation (EGR) valve fitting at this time. The fitting will be tightened after the intake is installed and the other fitting is connected to the EGR valve
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, possibly causing engine damage.
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.
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.
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 all traces of old sealant.
NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. 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:
Install new O-ring seals on the fuel injectors and lubricate them with clean engine oil.
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 all traces of old sealant.
NOTE:
Clean the valve cover gasket sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.