Section 1848 (Engine - 3.0L (4V)): Assembly: Engine

Courtesy of FORD MOTOR CO.	Compressor, Piston Ring 303-D032 (D81L-6002-C)
Courtesy of FORD MOTOR CO.	Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
Courtesy of FORD MOTOR CO.	Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH)
Courtesy of FORD MOTOR CO.	Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455
Courtesy of FORD MOTOR CO.	Installer, Connecting Rod 303-462 (T94P-6136-AH)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
Courtesy of FORD MOTOR CO.	Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A)
Courtesy of FORD MOTOR CO.	Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Courtesy of FORD MOTOR CO.	Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A)
Courtesy of FORD MOTOR CO.	Lifting Bracket, Engine 303-050 (T70P-6000)
Courtesy of FORD MOTOR CO.	Protector, Camshaft Oil Seal 303-463 (T94P-6256-AH)
Courtesy of FORD MOTOR CO.	Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455
Courtesy of FORD MOTOR CO.	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Lower Engine Block (View 1) 

Fig 1: Exploded View Of Lower Engine Block (View 1)

Courtesy of FORD MOTOR CO.

Lower Engine Block (View 2) 

Fig 2: Exploded View Of Lower Engine Block (View 2)

Courtesy of FORD MOTOR CO.

Cylinder Heads and Intake Manifolds 

Fig 3: Exploded View Of Cylinder Heads And Intake Manifolds

Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: This procedure is for selecting bearings using a new crankshaft.
1. 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 2 numbers after the asterisk make up the code for main No. 1 and the next 2 numbers for main No. 2.
      • The first 2 numbers after the second asterisk make up the code for main No. 3 and the last 2 numbers for main No. 4.
        Fig 4: Identifying Crankshaft Main Bearings

        Courtesy of FORD MOTOR CO.
2. 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 5: Crankshaft And Block Code Chart

     Courtesy of FORD MOTOR CO.
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
Fig 6: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
3. Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.
4. Lubricate the lower crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the lower cylinder block.
   Fig 7: Locating Bearings

   Courtesy of FORD MOTOR CO.
5. Lubricate the crankshaft thrust bearing with clean engine oil and install in the cylinder block.
   Fig 8: Locating Crankshaft Thrust Bearing

   Courtesy of FORD MOTOR CO.
6. Install the crankshaft key.
   Fig 9: Locating Crankshaft Key

   Courtesy of FORD MOTOR CO.
7. Apply clean engine oil to the crankshaft main and rod bearing journals.
8. Position the crankshaft in the cylinder block.
   Fig 10: Locating Crankshaft

   Courtesy of FORD MOTOR CO.
NOTE: The lower cylinder block must be installed and the bolts tightened within 4 minutes of applying the sealant.
NOTE: Clean and degrease both surfaces using metal surface prep before applying sealant.
Fig 11: Applying Gasket And Sealant To Cylinder Block
Courtesy of FORD MOTOR CO.
9. Apply gasket and sealant to the cylinder block as shown.
NOTE: Fasteners No. 5 through 8 are studs. Fasteners No. 18 through 22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 1 through 4, 17 are M8 x 1.25 mm x 96 mm (0.05 in x 3.75 in) bolts. Fasteners 9 through 12 are M10 x 1.5 mm x 106.8 mm (0.06 in x 4.20 in)/M8 x 1.25 mm x 21.5 mm (0.05 in x 0.84 in) studs. Fasteners 13 through 16 are M10 x 1.5 mm x 106.5 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.
10. Position the lower cylinder block and install the new bolts and new studs.
    • Tighten the bolts and studs in the sequence shown in 4 stages.
    • Stage 1: Tighten fasteners 1 through 8 to 25 Nm (18 lb-ft).
    • Stage 2: Tighten fasteners 9 through 16 to 40 Nm (30 lb-ft).
    • Stage 3: Tighten fasteners 1 through 16 an additional 90 degrees.
    • Stage 4: Tighten fasteners 17 through 22 to 25 Nm (18 lb-ft).
      Fig 12: Identifying Lower Cylinder Block Bolts In Sequence

      Courtesy of FORD MOTOR CO.
11. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
    • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge with Holding Fixture.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • Acceptable crankshaft end play is 0.100-0.255 mm (0.003-0.010 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
      Fig 13: Measuring Crankshaft End Play

      Courtesy of FORD MOTOR CO.
12. Using the Crankshaft Rear Main Oil Seal Installer and the Crankshaft Rear Main Oil Seal Installer Bolts, install the crankshaft rear oil seal.
    Fig 14: Identifying Crankshaft Rear Main Oil Seal Installer And Crankshaft Rear Main Oil Seal Installer Bolts

    Courtesy of FORD MOTOR CO.
13. Install the engine-to-transaxle separator plate.
    Fig 15: Locating Engine-To-Transaxle Separator Plate

    Courtesy of FORD MOTOR CO.
14. Position the flexplate and install the bolts.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 16: Locating Bolts And Flexplate

      Courtesy of FORD MOTOR CO.
15. Mount the engine on an engine stand.
16. Using the chart, select the correct piston grade size for the cylinder bores.
    • Measure the cylinder block bore diameter.
    • Mark the outside of the block with the appropriate number(s) to identify bore grade size.
    • Choose the correct piston grade size for the cylinder bore.
      Fig 17: Correct Piston Grade Size Chart

      Courtesy of FORD MOTOR CO.
NOTE: 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: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to Piston .
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
NOTE: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.
Fig 18: Identifying Piston Ring Compressor And Connecting Rod Installer
Courtesy of FORD MOTOR CO.
17. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
18. Install the connecting rod caps and the new bolts.
    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
      Fig 19: Locating Connecting Rod Caps Bolts

      Courtesy of FORD MOTOR CO.
19. Install the crankcase cover, a new gasket and the bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 20: Locating Oil Separator Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
20. Position the new LH and RH cylinder heads and gaskets. Install new bolts and tighten in the sequence shown in 6 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.
Fig 21: Identifying Cylinder Heads Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
21. Install the crankshaft pulley bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
Fig 22: Locating Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.
CAUTION: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
22. Install the hydraulic lash adjusters.
    • Lubricate the hydraulic lash adjusters with clean engine oil.
23. Apply clean engine oil to the LH and RH camshaft roller followers.
CAUTION: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE: RH shown, LH similar.
24. Install the LH and RH camshaft roller followers.
Fig 23: Locating Camshaft Roller Followers
Courtesy of FORD MOTOR CO.
25. Apply clean engine oil to the LH and RH camshafts.
26. Install the LH and RH camshafts.
    • Locate the camshafts as shown.
Fig 24: Locating Camshafts Matching Marks
Courtesy of FORD MOTOR CO.
CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
27. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
    • Loosely install the bolts.
Fig 25: Locating Camshaft Bearing Caps Installing Sequence
Courtesy of FORD MOTOR CO.
28. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
    • Loosely install the bolts.
Fig 26: Locating Camshaft Bearing Thrust Caps
Courtesy of FORD MOTOR CO.
29. Install the bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 27: Identifying Tightening Sequence Of Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps can occur.
30. Lubricate the bearing surfaces of the RH camshaft bearing caps with clean engine oil and install the bearing caps.
    • Loosely install the bolts.
Fig 28: Locating Camshaft Bearing Caps Installing Sequence
Courtesy of FORD MOTOR CO.
31. Lubricate the bearing surfaces of the RH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
    • Loosely install the bolts.
Fig 29: Locating Camshaft Bearing Thrust Caps
Courtesy of FORD MOTOR CO.
32. Install the bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 30: Identifying Tightening Sequence Of Bolts
Courtesy of FORD MOTOR CO.
NOTE: Clean the sealing surface with metal surface prep before installing a new press-in-place gasket.
33. Install the camshaft oil seal retainer and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 31: Locating Camshaft Oil Seal Retainer And Bolts
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
34. Using the special tools, install a new camshaft oil seal.
Fig 32: Identifying Special Tools (303-463, 303-464 And 211-185)
Courtesy of FORD MOTOR CO.
35. Remove the crankshaft pulley bolt.
Fig 33: Locating Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.
36. Install the crankshaft sprockets with the timing marks out.
Fig 34: Locating Crankshaft Sprockets With Timing Marks Out
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
37. Position the chain tensioner in a soft-jawed vise.
Fig 35: Identifying Chain Tensioner In Soft-Jawed Vise
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
38. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
Fig 36: Holding Chain Tensioner Ratchet Lock Mechanism Away From Ratchet Stem
Courtesy of FORD MOTOR CO.
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.
39. Slowly compress the timing chain tensioner.
40. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
Fig 37: Retaining Tensioner Piston With 1.5-mm (0.06-in) Wire Or Paper Clip
Courtesy of FORD MOTOR CO.
41. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
    1. Mark any link to use as the crankshaft timing mark.
    2. Starting with the crankshaft timing mark, count 29 links and mark the link.
    3. Continue counting to link 42 and mark the link.
Fig 38: Locating Crankshaft & Camshaft Timing Marks On LH & RH Timing Chains
Courtesy of FORD MOTOR CO.
42. Position the LH timing chain and guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
Fig 39: Aligning Marks On Timing Chain With Marks On Camshaft & Crankshaft Sprockets
Courtesy of FORD MOTOR CO.
43. Install the LH timing chain tensioner arm and the LH timing chain tensioner.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
    4. Tighten to 25 Nm (18 lb-ft).
Fig 40: Identifying Timing Chain Tensioner Arm & Bolts
Courtesy of FORD MOTOR CO.
44. Install the crankshaft pulley bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
Fig 41: Locating Crankshaft Keyway
Courtesy of FORD MOTOR CO.
45. Verify that the RH camshafts are correctly positioned.
Fig 42: Aligning Marks RH Camshafts
Courtesy of FORD MOTOR CO.
46. Install the RH timing chain and chain guide and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
Fig 43: Aligning Marks On Timing Chain With Marks On Camshaft & Crankshaft Sprockets
Courtesy of FORD MOTOR CO.
47. Install the RH timing chain tensioner and tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
    4. Tighten to 25 Nm (18 lb-ft).
Fig 44: Identifying Tensioner Arm, Tensioner And Bolts
Courtesy of FORD MOTOR CO.
48. Remove the LH and RH timing chain tensioner piston retaining wires.
49. Rotate the crankshaft counterclockwise 120 degrees to TDC.
CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.
50. 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 45: Checking Chain Links Timing Marks
Courtesy of FORD MOTOR CO.
51. Remove the crankshaft pulley bolt.
Fig 46: Identifying Damper Bolt
Courtesy of FORD MOTOR CO.
NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" only (orange in color).
52. Install the ignition pulse wheel.
Fig 47: Identifying Ignition Pulse Wheel
Courtesy of FORD MOTOR CO.
53. Install 3 new gaskets in the front cover.
NOTE: Clean and degrease the sealing surfaces with metal surface prep before applying gasket and sealant.
NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.
54. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
Fig 48: Applying Sealant To Cylinder Block
Courtesy of FORD MOTOR CO.
NOTE: Fasteners 1 and 13 are stud bolts.
55. Position the front cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 25 Nm (18 lb-ft).
Fig 49: Identifying Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.
56. Using the special tools, install the crankshaft front oil seal.
Fig 50: Installing Crankshaft Seal Using Special Tools (303-335 And 303-102)
Courtesy of FORD MOTOR CO.
NOTE: Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant.
NOTE: Sealing surfaces must be free of dirt and oil.
NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of sealant application.
57. Apply silicone gasket and sealant to the end of the crankshaft pulley keyway slot.
Fig 51: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the outside diameter sealing surface with clean engine oil.
58. Using the special tool, install the crankshaft pulley.
Fig 52: Installing Crankshaft Pulley Using Special Tools (303-102, 303-335)
Courtesy of FORD MOTOR CO.
59. Install the crankshaft pulley washer and tighten the bolt in 4 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 53: Locating Crankshaft Vibration Damper Washer & Bolt
Courtesy of FORD MOTOR CO.
60. Install the belt tensioner and the bolt.
    • Tighten to 45 Nm (33 lb-ft).
Fig 54: Locating Belt Tensioner & Bolt
Courtesy of FORD MOTOR CO.
61. Install the LH idler pulley and the bolt.
    • Tighten to 47 Nm (35 lb-ft).
Fig 55: Identifying pulley And Bolt
Courtesy of FORD MOTOR CO.
62. Install the center idler pulley and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 56: Locating Idler Pulley & Bolt
Courtesy of FORD MOTOR CO.
63. Position the oil pan baffle. Install the nuts and tighten in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten 45 degrees.
Fig 57: Locating Oil Pan Baffle And Nuts
Courtesy of FORD MOTOR CO.
64. Install a new O-ring seal on the oil pump screen and pickup tube. Lubricate with clean engine oil.
Fig 58: Locating O-Ring Seal
Courtesy of FORD MOTOR CO.
65. Install the oil pump screen and pickup tube.
    1. Position the oil pump screen and pickup tube.
    2. Install the bolts.
    3. Install the nut and tighten in 2 stages.
       • Stage 1: Tighten to 5 Nm (44 lb-in).
       • Stage 2: Tighten 45 degrees.
Fig 59: Identifying Oil Pump Screen, Pickup Tube & Bolts
Courtesy of FORD MOTOR CO.
66. Install the new gasket in the LH valve cover in the following sequence.
    1. Install the gasket at waffle pads and then the corners.
    2. Install the gasket around bolt holes.
    3. Install the remaining part of the gasket.
       Fig 60: LH Valve Cover Gasket Tightening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.
NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.
67. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
68. Position the LH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 61: Identifying Tightening Sequence Of Valve Cover Bolts & Studs
Courtesy of FORD MOTOR CO.
69. Install the new gasket in the RH valve cover in the following sequence.
    1. Install the gasket at waffle pads and then the corners.
    2. Install the gasket around bolt holes.
    3. Install the remaining part of the gasket.
       Fig 62: RH Valve Cover Gasket Tightening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: The valve cover must be installed and the bolts and studs tightened within 4 minutes of sealant application.
NOTE: Clean cylinder head and front cover surface using metal surface prep before applying silicone gasket and sealant.
70. Apply an 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
Fig 63: Locating Silicone Gasket And Sealant Area
Courtesy of FORD MOTOR CO.
71. Position the RH valve cover and install the bolts and stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 64: Identifying Tightening Sequence Of Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
72. Install the radio interference capacitor and the nut.
    • Tighten to 6 Nm (53 lb-in).
Fig 65: Locating Radio Interference Capacitor Nut
Courtesy of FORD MOTOR CO.
73. Install the coolant pump and the bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 66: Locating Coolant Pump & Bolts
Courtesy of FORD MOTOR CO.
74. Connect the coolant pump hose to the cylinder block outlet.
Fig 67: Locating Coolant Pump Hose From Cylinder Block Outlet
Courtesy of FORD MOTOR CO.
75. Install the bypass tube and the nut and bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 68: Locating Coolant Bypass Tube Bolt & Nut
Courtesy of FORD MOTOR CO.
76. Position the coolant tube and connect the hoses.
Fig 69: Locating Coolant Tube
Courtesy of FORD MOTOR CO.
CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
77. Install the special tool in the camshaft as shown in the illustration.
    • Adjust the collar on the special tool screw to get the best thread engagement in the rear of the camshaft.
Fig 70: Installing Special Tool On Camshaft
Courtesy of FORD MOTOR CO.
CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-485).
78. Position the coolant pump pulley over the previously installed special tool and on the end of the camshaft. Install the special tools as shown in the illustration.
    • Using the special tools, install a new service coolant pump pulley flush with the end of the camshaft.
Fig 71: Installing Coolant Pump Pulley Using Special Tools (211-185, 303-458, 303-459)
Courtesy of FORD MOTOR CO.
79. Install the coolant pump belt on the coolant pump pulley and position it on the camshaft pulley.
Fig 72: Locating Coolant Pump Belt On Coolant Pump Pulley
Courtesy of FORD MOTOR CO.
CAUTION: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or camshaft pulley while installing the belt.
80. Rotate the crankshaft clockwise to seat the water pump belt on the camshaft pulley.
81. Lubricate the O-ring seal and install the oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
Fig 73: Identifying Oil Filter
Courtesy of FORD MOTOR CO.
82. Install 6 new LH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
Fig 74: Locating Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
83. Install a new gasket and the LH exhaust manifold and new nuts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
Fig 75: Identifying Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Make sure to apply anti-seize lubricant to the threads of the heated oxygen sensor (HO2S) before installation.
84. Using the special tool, install the LH HO2S.
    • Tighten to 47 Nm (35 lb-ft).
Fig 76: Identifying Special Oxygen Sensor Tool
Courtesy of FORD MOTOR CO.
85. Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.
Fig 77: Locating O-Ring On Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
86. Position the oil level indicator and tube and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 78: Oil Level Indicator Tube & Nut
Courtesy of FORD MOTOR CO.
87. Install the engine oil pressure (EOP) switch and, if equipped, the block heater.
    • Tighten the EOP switch to 14 Nm (10 lb-ft).
    • Tighten the block heater to 21 Nm (15 lb-ft).
Fig 79: Locating Oil Pressure Sender
Courtesy of FORD MOTOR CO.
88. Install the 3 bolts and the A/C compressor bracket.
    • Tighten to 25 Nm (18 lb-ft).
Fig 80: Identifying Bolts
Courtesy of FORD MOTOR CO.
89. Position the generator and install the bolt and 2 nuts.
    • Tighten to 47 Nm (35 lb-ft).
Fig 81: Identifying Bolt And Nuts
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

90. Install the halfshaft support bracket and the bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 82: Locating Halfshaft Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
91. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
Fig 83: Locating Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
92. Install a new gasket and the RH exhaust manifold and new nuts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
Fig 84: Identifying Tightening Sequence Of RH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
93. Connect the RH HO2S electrical connector.
Fig 85: Identifying RH HO2S Connector
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: LH shown, RH similar.

Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

94. Install the 6 coil-on-plugs and the bolts.
    • Tighten to 6 Nm (53 lb-in).
Fig 86: Coil-On-Plug Bolts
Courtesy of FORD MOTOR CO.
NOTE: Install new gaskets.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
95. Install the lower intake manifold and the bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 87: Identifying Tightening Sequence Of Lower Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
96. Install the B+ wiring harness on the engine.
    • Attach the 4 wiring harness retainers, and install the nut.
    • Tighten to 6 Nm (53 lb-in).
Fig 88: Identifying Retainers And Nut
Courtesy of FORD MOTOR CO.
97. Position the fuel charging wiring harness on the engine.
    • Attach the 2 wiring harness retainers (1 shown) to the engine.
Fig 89: Identifying Retainer
Courtesy of FORD MOTOR CO.
98. Connect the fuel injector electrical connectors.
Fig 90: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
99. Install the B+ wire and nut on the generator.
    • Tighten to 8 Nm (71 lb-in).
Fig 91: Identifying Nut
Courtesy of FORD MOTOR CO.
100. Connect the generator electrical connector.
Fig 92: Identifying Connector
Courtesy of FORD MOTOR CO.
101. Connect the camshaft position sensor (CMP) and EOP switch electrical connectors.
     • Attach the wiring retainers.
Fig 93: Locating Camshaft Position Sensor (CMP) & Oil Pressure Sensor Electrical Connectors & Wiring Retainers
Courtesy of FORD MOTOR CO.
102. Connect the LH coil-on-plug electrical connectors.
     • Attach the 2 wiring retainers.
Fig 94: Coil-On-Plug Electrical Connectors & Wiring Retainers
Courtesy of FORD MOTOR CO.
103. Connect the radio interference capacitor electrical connector.
     • Attach the wiring retainers.
Fig 95: Locating Radio Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
104. Connect the RH coil-on-plug electrical connectors.
     • Attach the 2 wiring harness retainers.
Fig 96: Identifying Connectors
Courtesy of FORD MOTOR CO.
105. Connect the engine coolant temperature (ECT) sensor electrical connector.
Fig 97: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: Install new gaskets.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
106. Install the upper intake manifold and the bolts.
     • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 98: Identifying Tightening Sequence Of Upper Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
107. Connect the throttle body (TB) coolant hose.
Fig 99: Locating Throttle Body Coolant Hose
Courtesy of FORD MOTOR CO.
108. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
Fig 100: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
109. Install the PCV tube.
Fig 101: Identifying PCV Tube
Courtesy of FORD MOTOR CO.
110. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
     • Attach the wiring retainer.
Fig 102: Identifying (IAC) Valve And (TP) Sensor Connectors
Courtesy of FORD MOTOR CO.
111. Position the engine control wiring harness and install the nuts.
     • Tighten to 6 Nm (53 lb-in).
Fig 103: Locating Engine Control Wiring Harness & Nuts
Courtesy of FORD MOTOR CO.
112. Connect the EGR vacuum regulator electrical connector.
Fig 104: Identifying Connector
Courtesy of FORD MOTOR CO.
113. Connect the crankshaft position (CKP) sensor electrical connector and attach the wiring retainers.
Fig 105: Locating Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
114. Position the catalyst monitor sensor electrical connector bracket. Install the nut and attach the wiring retainer.
     • Tighten to 10 Nm (89 lb-in).
Fig 106: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Bracket
Courtesy of FORD MOTOR CO.
115. Attach the engine control sensor wiring connectors to the upper intake manifold.
Fig 107: Locating Engine Control Sensor Wiring Connectors
Courtesy of FORD MOTOR CO.
116. Using the special tools, remove the engine from the engine stand.
Fig 108: Aligning Engine With Transaxle
Courtesy of FORD MOTOR CO.