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Home >> Ford >> 1999 >> Windstar V6-3.0L VIN U >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Assembly
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Assembly


Special Tools:










1. CAUTION: The crankshaft main bearings are precision fit.

Install the upper crankshaft main bearings.





2. Note: Lubricate the crankshaft journals and the crankshaft main bearings with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Position the crankshaft.





3. Note: Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the crankshaft rear oil seal.





4. Apply two dots of Gasket Maker between the rear bearing cap and the cylinder block.
- Use Gasket Maker F8A-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5.





5. Install the lower crankshaft main bearings.





6. Install the main bearing caps.





7. Install the main bearing cap bolts.
- Tighten the bolts in pairs.
- Carry out the crankshaft and crankshaft bearing component tests.





8. If removed, install the camshaft bearings.





9. Note: Lubricate the camshaft and the camshaft bearings with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the camshaft.





10. Install the camshaft thrust plate.
11. Inspect the camshaft end play.





12. Align the timing marks.





13. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.





14. Install the camshaft sprocket bolt.





15. Note: Lubricate the piston and connecting rod assemblies with clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the piston and connecting rod assemblies.

16. Note: Lubricate the connecting rod bearings with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the connecting rod bearings.





17. Install the connecting rod caps and nuts.
- Tighten the nuts in pairs.





18. Install the oil pump.





19. Note: Lubricate the valve tappets with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the valve tappets.





20. Install the valve tappet guide plates.





21. Install the valve tappet guide plate retainer.





22. Install new head gaskets.





23. Position the cylinder heads.





24. Install the bolts. Tighten the bolts in the sequence shown in five stages.
- Stage 1: Tighten the bolts to 50 Nm (37 inch lbs.)
- Stage 2: Loosen the bolts one full term.
- Stage 3: Tighten to 30 Nm (22 ft. lbs.).
- Stage 4: Rotate an additional 85-95°.
- Stage 5: Rotate an additional 85-95°.





25. Install the oil bypass filter.
- Advance the filter one half turn after gasket contacts the sealing surface.

26. Install the exhaust manifolds.





27. Install the oil level indicator tube.





28. Install the EGR valve to exhaust manifold tube.





29. Install a new engine front cover gasket and the engine front cover.





30. Note: Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 on the bolts to be installed in the locations shown.
Install the engine front cover and bolts.





31. Install the crankshaft position (CKP) sensor.





32. Apply four beads of Gasket Maker as shown.
- Use Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5.





33. Position the oil pan gasket.





34. Position the oil pan and hand-start the bolts.





35. Install the bolts.
- Tighten the bolts in four stages:
- Stage 1: Tighten the four corner bolts to 12 Nm (9 inch lbs.).
- Stage 2: Tighten the remaining bolts to 12 Nm (9 inch lbs.).
- Stage 3: Loosen all the bolts one turn.
- Stage 4: Tighten all the bolts to 12 Nm (9 inch lbs.).
36. Install the camshaft synchronizer.





37. Apply four beads of Silicone Gasket and Sealant.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





38. Position the intake manifold gaskets and end seals.





39. Install the lower intake manifold.
- Tighten the bolts in two stages.
- Stage 1: Tighten to 15 Nm (11 ft. lbs.).
- Stage 2: Tighten to 32 Nm (24 ft. lbs.).





40. Install the fuel injection manifold and fuel injectors as an assembly.





41. Install the push rods and the rocker arms.
- Install the push rods.
- Install the rocker arms.
- Tighten the bolts in two stages:
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Tighten to 32 Nm (24 ft. lbs.).





42. Apply a bead of Silicone Gasket and Sealant to the four intake-to-cylinder head seams.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





43. If removed, install the valve cover gaskets.





44. Install the valve covers.
- Tighten the bolts in the sequence shown.





45. Install the ignition coil and spark plug wires as an assembly.
- Position the ignition coil and wires.
- Install the bolts.





46. Install the spark plug wire retainers.





47. Install the fuel charging wire harness.





48. Connect the CKP connector.





49. Connect the fuel injectors.





50. Install a new upper intake manifold gasket.





51. Install the upper intake manifold.
- Tighten the bolts in the sequence shown.





52. Install the positive crankcase ventilation (PCV) valve.





53. Install the EGR valve.
- Install the gasket.
- Install the EGR valve.
- Install the bolts.
- Tighten the nut.





54. Install the bolt.
- Position the bracket.
- Install the bolt.

55. Install the crankshaft damper.





56. Install the bolt.





57. Install the crankshaft pulley.
- Position the pulley.
- Install the bolts.





58. Install the water pump pulley.
- Position the pulley.
- Install the bolts.
59. Install the power steering pump and the power steering pump bracket.
60. Install the air conditioning compressor and bracket.
61. Install the generator and the generator mounting bracket.
62. Connect the oil pressure switch.





63. Connect the electrical connectors.
- Connect the engine coolant temperature (ECT) sensor.
- Connect the camshaft position (CMP) sensor.





64. Connect the electrical connectors.
- Connect the differential pressure feedback EGR.
- Connect the throttle position (TP) sensor.
- Connect the idle air control (IAC).





65. Install the vacuum harness Position the vacuum harness.
- Connect the vacuum harness.





66. Connect the vacuum harness.
67. Connect the spark plug wires.

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