Installation

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

1. Preparatory operations

CAUTION: Do not damage the cylinder liners. Remove the ring of carbon from the upper edge of the cylinder.

^ Remove any gasket residues with Gasket eliminator and a Spatula.
^ Thoroughly clean the threaded bores for the cylinder head bolts.

2. Check the cylinder head distortion.





3. Position a new cylinder head gasket on the cylinder block and put on the cylinder head.
^ Hook the cylinder head by the engine lifting eyes into the Workshop hoist and position it on the cylinder block.





4. CAUTION: The cylinder head bolts must not be tightened more than once.

Install the bolts in the sequence shown in three stages:
^ Stage 1: Tighten bolt 1 through 10 to 25 Nm
^ Stage 2: Tighten bolt 1 through 10 to 45 Nm
^ Stage 3: Tighten bolt 1 through 10 to 105 degrees.





5. Install the special tools.





6. NOTE: Use a thumb to press the positioning pins on the gasket into the holes.

Press a new gasket into the oil feed flange.





7. Prepare the exhaust camshaft for installation.
1 Insert the oil feed ring into the oil feed flange.
2 Slide both components together onto the exhaust camshaft.





8. Thinly coat camshaft bearing cap No. 5 with Black silicone rubber.





9. Insert the camshafts.
^ Lubricate the valve tappets with Engine assembly lubricant and insert them.
^ Lubricate the camshaft bearings with Engine assembly lubricant.
^ Insert the intake camshaft.

1 Hold the oil feed flange upwards during installation of the exhaust camshaft.
2 Bring the oil feed ring hole right to the top.

NOTE: Keep the oil feed flange away from the cylinder head when turning the flange to avoid damaging the gasket.

3 Turn the oil feed flange till the locating lug is in installation position on the cylinder head.
10. Insert new camshaft oil seals.





11. NOTE: The numbering is on the outside of the camshaft bearing caps.

Insert the camshaft bearing caps.





12. NOTE: Working evenly in several stages, screw in each bolt two turns at a time.

Tightening sequence of the camshaft bearing caps.





13. NOTE: Tightening sequence.

Tighten the bolts.





14. NOTE: Location lug of the oil feed flange is in installation position on the cylinder head during installation.

Screw in the oil feed flange bolts and the upper timing case bolts.
^ Hand-tighten the right-hand bolt.
^ Hand-tighten the left-hand bolt.

1 Tighten the night-hand bolt.
2 Tighten the left-hand bolt.





15. NOTE: After carrying out the check turn the hole right up to the top.

Check that the oil feed ring moves freely.
^ If it is difficult to turn the oil feed ring, loosen the bolts on the oil feed flange and tighten them again as described in step.





16. Set the crankshaft to TDC on cylinder No. 1.





17. Unscrew the blanking plug. Using special tool, set the crankshaft to TDC.





18. Set cylinder No. 4 to valves overlap and install the special tool.
1 Hold the camshafts by the hexagon using an open-ended wrench and turn them in the direction of engine rotation.
2 Slide special tool onto the ends of both camshafts.





19. NOTE: If the lug is not centered between the oil bores and the mark, renew the exhaust camshaft pulley.

Installation position of the exhaust camshaft pulley.
1 The lug is centered between the oil bores and the mark.
2 The lug must locate in the hole.

CAUTION: Do not rotate the crankshaft; as necessary check that it is still resting against the special tool 303-574.





20. NOTE: The lug of the tensioner should not be hooked in the sheet metal cover during timing belt assembly.

Timing belt routing.
^ Starting from the crankshaft timing belt pulley and working counter-clockwise, position the timing belt in place while keeping it under tension.

NOTE: Install the bolts in place but do not yet tighten at this stage.





21. NOTE: New O-ring seal for the exhaust camshaft pulley.

Slide the pulleys onto the camshafts, screw in the bolts and position the new timing belt in place, working counterclockwise.
1 Position the hollow bolt.
2 Install the bolt.





22. CAUTION: Tension the timing belt, working counterclockwise.

NOTE: Incorrect timing belt tension will cause incorrect valve timing.

Tension the timing belt.
1 Hook the timing belt tensioner into the sheet metal cover and loosely screw in the bolt.
2 Tension the belt by turning the timing belt tensioner counter-clockwise until the pointer and the mark are lined up.





23. Tighten the timing belt pulleys.
1 Tighten the intake camshaft pulley bolt.

NOTE: Hold the exhaust camshaft by the hexagon with an open-ended wrench to stop it from turning.

2 Tighten the exhaust camshaft pulley bolt.
24. Remove the special tool 303-574.

25. Remove the special tool 303-465 from the camshafts.





26. NOTE: Hold the camshaft by the hexagon with an open-ended wrench to stop it from turning.

Tighten the exhaust camshaft on Stage 2.

27. NOTE: As necessary, only turn engine in direction of engine rotation by the crankshaft.

Check camshaft timing.
^ Carry out steps to
^ If special tool 303-465 does not fit into both camshaft slots, loosen the tensioner, the intake and exhaust camshaft pulley bolts and carry out steps.





28. NOTE: Install a new blanking plug.

Screw in the new blanking plug on the exhaust camshaft timing belt pulley.





29. NOTE: Tightening sequence: From the inside outwards, working diagonally.

Install the valve cover.
1 Install the ten bolts.
2 Connect the crankcase ventilation hose.
3 Connect the HT wires to the spark plugs.





30. Install the appearance cover plate.
1 Install the bolts,
2 Connect the solenoid valve connector and press in the rubber seal.





31. Install the center part of the engine front cover/front engine mounting bracket.





32. Install the upper part of the engine front cover.
1 Install in the bolts.

NOTE: Use a Torx E10.

2 Install the studs.





33. NOTE: One bolt also holds the power steering line bracket.

Install the front engine mounting.
34. Remove the special tools 303-290A, 303-290-01, 303-290-02 and 303-290-03.
35. Raise and support the vehicle.

Vehicles with automatic transaxle





36. Secure the right-hand engine support insulator.
1 Tighten the bolt.
2 Install the vibration damper.





37. Tighten the bolt of the right-hand engine support insulator.

Vehicles with manual transaxle





38. Tighten the bolts on the right-hand engine support insulator.
1 On the subframe.
2 On the transaxle mounting bracket.





39. Install the left-hand engine support insulator.
^ Remove the bracket of the left-hand engine support insulator from the transaxle.
^ Install the engine support insulator in the subframe.
^ Install the bracket again.

Vehicles with automatic transaxle
40. Install the left-hand engine support insulator.
^ Raise the engine/transaxle assembly slightly using the Hi-Lift Transmission Jack and install the left-hand engine support insulator.

All Vehicles





41. Install the left-hand engine support insulator.
1 Install the engine support insulator to the subframe.
2 Tighten the bolt.





42. Connect the oil pressure switch and the knock sensor electrical connector.





43. Install the brake booster line and the crankcase ventilation hose to the intake manifold.





44. Screw in the lower power steering pump bolts.





45. Install the lower part of the engine front cover.





46. Install the crankshaft pulley vibration damper.





47. Install the accessory drive belt.
1 Install the idler pulley.

NOTE: Do not fully tighten the bolts at this stage.

^ Install the water pump pulley.

2 Tension the belt tensioner clockwise and position the drive belt in place.
3 Tighten the water pump pulley bolts.





48. Install the lower right-hand fender splash shield.
^ Position the right-hand front wheel.





49. Install the lower radiator splash shield.
1 Tighten the coolant drain plug.
2 Install the six bolts.





50. Install the engine undershield.
51. Lower the vehicle.





52. Install the generator bracket.





53. Install the generator.
1 Install the bolts.
2 Connect the generator.





54. Install the power steering pump and the coolant expansion tank.
1 Install the coolant expansion tank.
^ Attach the speed control cable to the coolant expansion tank.

2 Connect the coolant hose to the coolant expansion tank.
3 Install in the upper power steering pump bolts.
4 Attach the power steering pump bracket.





55. Install the pulley cover.





56. Attach the TWC to the exhaust manifold.
^ Connect the H02S electrical connector and attach it.





57. Install the heat shield.
^ Insert the oil level indicator tube, and position the coolant hose bracket and the engine lifting eye.

1 Install in the upper bolts.
2 Install the bracket for the tube/hose (A/C).
3 Install the lower bolts.





58. Install the bracket for the crankcase ventilation line.





59. Install the thermostat housing with a new O-ring seal.
1 Connect the CMP sensor electrical connector.
2 Install in the bolts.
3 Connect the coolant hoses.





60. Connect the electrical connectors:
1 Radio interference suppressor.
2 Ignition coil.
3 Engine Coolant Temperature (ECT) sensor.
4 Power Steering Pressure (PSP) switch.





61. Connect the positive lead of the starter motor.

CAUTION: Do not bend the fusible element when tightening the nut as there is a risk of breaking it.

^ Install the nut.
^ Install the cover.





62. Install the wiring rail and connect the vacuum hoses.
^ Screw in the upper wiring rail bolts.
^ Connect the vacuum hoses.
^ Connect the cylinder head wiring harness electrical connector.





63. Connect and adjust the throttle cable.
1 Install the cable in the bracket and slide on the plastic clip.
^ Hook the cable in place.

2 Remove the clip from the throttle cable.
^ Pull the inner cable a few clicks out from the outer cable.
^ Fully depress the accelerator pedal once and slide the clip back on.
^ Check whether the throttle valve opens fully when the accelerator pedal is fully depressed - repeat adjustment as necessary.





64. Attach the speed control cable.
1 Press the retaining bush into the bracket.

NOTE: An audible click indicates that it has snapped into place.

2 Slide the cable into the retaining bush.
3 Connect the cable to the throttle valve.





65. Install the air cleaner (ACL).
1 Press the ACL into the rubber mountings and hook the rubber ring in place.
2 Connect the intake hose.
3 Connect the crankcase ventilation hose.





66. Install the intake pipe.
1 Secure the retaining clips.
2 Install the bolt and the two nuts.
3 Connect the IAT sensor electrical connector.
4 Connect the plug of the MAF sensor electrical connector.
67. Coolant - fill.





68. Tighten the RH front wheel.

69. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 Km (10 miles) or more to relearn the strategy.

Connect the battery ground cable.
70. Check the fluid levels and correct as necessary.
71. Check the routing of the vacuum hoses and wiring and secure them with Cable ties.

72. NOTE: The engine oil temperature must be at least 80°C.

Ford super premium engine oil SAE 5W-30 and oil Filter - change.

73. Check the fluid level again and correct as necessary.