Steps 61 - 125
NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure.
61. Install the oil filter.
62. Install the water pump.
63. NOTE: LH shown, RH similar.
Install the cylinder head gasket.
64. NOTE: LH shown, RH similar.
Install the cylinder head and tighten the bolts in the sequence shown.
65. NOTE: LH shown, RH similar.
Install the two 8 mm bolts.
66. NOTE: LH shown, RH similar.
Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten fasteners 1-4 to 32 Nm (24 ft. lbs.).
- Stage 2: Tighten fasteners 5-8 to 32 Nm (24 ft. lbs.).
- Stage 2: Rotate an additional 90 degrees.
67. Using the special tool, install the crankshaft pulley.
68. CAUTION: A new bolt must be used each time it is removed.
Tighten the bolt in two stages.
- Stage 1: Tighten to 50 Nm (37 ft. lbs.).
- Stage 2: Rotate an additional 90 degrees.
69. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the RH rear camshaft bolt.
70. Install the bolt.
71. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the LH front camshaft bolt.
72. Install the bolt.
73. Turn the crankshaft one revolution clockwise.
74. NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at Top Dead Center (TDC).
Install the special tool.
75. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.
Install the special tools on the front of the RH cylinder head.
76. NOTE: Leave the top two special tool clamp bolts loose.
Install the special tools on the rear of the RH cylinder head.
77. Install the special tool.
78. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
Tighten the bolts.
1 Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt.
79. Remove the special tool and install the RH camshaft tensioner.
80. Remove the special tools from the RH cylinder head.
81. NOTE: Do not tighten the special tool top two clamp bolts. Camshaft sprocket must rotate freely.
Install the special tools on the front of the LH cylinder head.
82. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.
Install the special tools on the rear of the LH cylinder head.
83. Install the special tool.
84. Tighten the bolts.
1 Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.).
2 Tighten the camshaft bolt.
85. Remove the special tool and install the LH camshaft tensioner.
86. Remove the special tools from the LH cylinder head.
87. Remove the special tool.
88. NOTE: Lubricate the parts with clean engine oil.
Using the special tool, install the roller followers in their original position.
89. Install the gasket and the RH exhaust manifold.
90. Install the gasket and the LH exhaust manifold.
91. NOTE: Prior to installation, use metal surface cleaner to clean mating surfaces.
Install the knock sensor.
92. Install the oil level indicator tube.
93. Install the thermostat housing.
1 Install the bypass hose onto the water pump.
2 Install the bolts.
3 Position the bypass hose clamp.
94. Install the RH valve cover and gasket.
95. Install the LH valve cover and gasket.
96. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings seals can cause the fuel system to leak. Do not reuse the O-ring seals.
Install new O-ring seals on each of the fuel injectors.
97. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil.
Install the fuel injectors.
98. Install the fuel injection supply manifold.
99. Position the vacuum harness on the engine and connect the fuel pulse damper vacuum hose.
100. Position the fuel charging wiring harness on the engine.
101. Install the fuel charging wiring harness retainers.
102. Connect the Crankshaft Position (CKP) sensor electrical connector.
103. Install the wiring anchors.
104. Connect the coolant temperature sensor electrical connector.
105. Connect the left side fuel injector electrical connectors.
106. Connect the right side fuel injector electrical connectors.
107. Install the hose.
108. Install the fuel supply tube to right valve cover retaining bolt.
109. Install the EGR tube.
110. Install the coolant tube.
111. Install the heater water hose and the bracket bolt.
112. Connect the heater control valve vacuum hose.
113. Install the lower heater water hose and clamp.
114. Install the lower radiator hose and clamp.
115. Install the heater hose to the thermostat housing.
116. Connect the upper radiator hose to the thermostat housing.
117. Install the hose.
118. Install the coil and bracket assembly.
119. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.
NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.
Connect the left spark plug wires.
120. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.
NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.
Connect the right spark plug wires.
121. Connect the following:
- Camshaft Position (CMP) sensor electrical connector.
- Ignition coil electrical connector.
- Pin-type retainer.
122. Install the generator mounting bracket.
1 Install the generator mounting bracket bolts.
2 Install the drive belt tensioner bolt.
123. Install the accessory bracket and tighten the bolts.
124. Rotate the drive belt tensioner counterclockwise and install the drive belt.
125. Install the A/C hose.