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 Maker F8AZ-19B508-AB meeting Ford specification WSK-M2G348-A5 and a Spatula.
^ Thoroughly clean the threaded bores for the cylinder head bolts.
^ Check the cylinder head distortion.





2. Install the cylinder head.
1. Make sure the upright seat of the guide sleeves.
2. Position a new cylinder head gasket onto the cylinder block.
^ Attach the cylinder head into the workshop hoist by the lifting eyes and position it on the cylinder block.

3. 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 20 Nm.
^ Stage 2: Tighten bolt 1 through 10 to 40 Nm.
^ Stage 3: Tighten bolt 1 through 10 to 90 degrees.





4. Install the special tools.

5. Note: Use a thumb to press the locating pins of the gasket into the holes.





Press a new gasket into the oil feed flange.





6. 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.





7. Thinly coat camshaft bearing cap No. 5 with Silicone Gasket and Sealant F7AZ-19554-EA meeting Ford specification WSE-M4G323-A4.





8. Insert the camshafts.
^ Lubricate the valve tappets with Super Premium SAE 5W30 Motor Oil XO-5W30QSP meeting Ford specification WSS-M2C 153G and insert them.
^ Lubricate the camshaft bearings with Super Premium SAE 5W30 Motor Oil XO-5W30QSP meeting Ford specification WSS-M2C153G.
^ Insert the intake camshaft.

1. Hold the oil feed flange upwards during installation of the exhaust camshaft.
2. Position 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.

9. Insert new exhaust camshaft oil seal.

10. Note: The numbering is on the outside of the camshaft bearing caps.





Insert the camshaft bearing caps.

Note: Make sure the upright seat of the exhaust camshaft oil seal during tightening process of camshaft bearing caps.

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

Note: Tighten the caps in the indicated sequence.





Tighten the camshaft bearing bolts.





12. Using the special tool, press in the intake camshaft oil seal.

13. 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.
^ Finger-tighten the right-hand bolt.
^ Finger-tighten the left-hand bolt.

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





14. 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





15. Position the crankshaft to TDC on cylinder No. 1.

16. Note: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key points straight up.





Remove the blanking plug. Using the special tool and set the crankshaft to TDC.





17. 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.

18. Note: If the lug is bent not centered between the oil bolts and the mark, install a new 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. Check that It is still resting against the special tool 303-574.

19. Note: Install the bolts but do not tighten at this stage.

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





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

20. Caution: Do not rotate the crankshaft. Check that it is still resting against the special tool 303-574.

Note: Design with lower idler pulley shown (built up to 06/1999).

Note: The lug of the belt tensioner should not be hooked in the sheet metal cover during timing belt installation.





Position a new timing belt in place.
^ Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.

21. Caution: Do not rotate the crankshaft. Check that it is still resting against the special tool 303-574.

Note: Design without lower idler pulley shown (built 06/1999 onwards).

Note: The lug of the belt tensioner should not be hooked in the sheet metal cover during timing belt installation.





Position a new timing belt in place.
^ Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.

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. Note: Hold the intake timing belt pulley with special tool to stop it from turning.





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

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

2. Tighten the exhaust camshaft timing belt pulley on stage 1.

24. Remove the special tool 303-574.

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





Tighten the exhaust camshaft on Stage 2.

26. Note: If necessary, only turn engine in direction of engine rotation by the crankshaft.

Check camshaft timing.
^ Set the crankshaft to TDC on cylinder No. 1 as described before.
^ If special tool 303-465 does not fit into both camshaft slots, loosen the tensioner, the intake and exhaust camshaft pulley bolts and tension the timing belt.

27. Note: Install a new blanking plug.





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

28. 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.





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





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





31. Install the upper pan of the engine front cover.
1. Install in the bolts.

Note: Use a Torx E10 bit.

2. Install the studs.

32. Note: One bolt also holds the power steering line bracket.





Install the front engine mounting.

33. Remove the special tools 303-290A, 303-290-01, 303-290-02 and 303-29OA-03A.
34. Raise and support the vehicle.

Vehicles With Automatic Transaxle





35. Tighten the bolt of the fight-hand engine support insulator.

Vehicles With Manual Transaxle





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

Vehicles With Manual Transaxle





37. 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
38. 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

39. Caution: Do not tilt the engine support insulator.





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





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





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





42. Screw in the lower power steering pump bolts.





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





44. Install the crankshaft pulley/vibration damper.





45. 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.





46. Install the right-hand lower splash shield.
47. Position the right-hand front wheel.





48. Install the lower radiator splash shield.
1. Tighten the coolant drain plug.
2. Install the seven bolts.





49. Install the engine undershield (if equipped).
50. Lower the vehicle.
51. Secure the right-hand front wheel.





52. Install the generator bracket.





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





54. Install the power steering pump.
1. Install the upper power steering pump bolts.
2. Attach the power steering pump bracket to the cylinder head.





55. Install the coolant expansion tank. Attach the speed control cable (if equipped) to the coolant expansion tank.





56. Install the pulley cover.





57. Connect the TWC to the exhaust manifold.
58. Connect the H02S electrical connector.





59. Install the exhaust manifold 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.





60. Install the positive crankcase ventilation line clamp.





61. 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.





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





63. 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.





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





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





66. 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.





67. Install the Air Cleaner (ACL).
^ Press the ACL into the rubber mountings.
1. Connect the crankcase ventilation hose.
2. Connect the intake hose.





68. Install the intake pipe.
1. Install the bolt and the two nuts.
2. Connect the plug of the MAF sensor electrical connector.
3. Connect the IAT sensor electrical connector.

69. Fill the cooling system.





70. Tighten the right-hand front wheel.

71. 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.

72. Check the fluid levels and correct as necessary.
73. Check the routing of the vacuum hoses and wiring and secure them with Cable ties .

74. Note: The engine oil temperature must be at least 800C Super Premium SAE 5W30 Motor Oil XO-5W30QSP meeting Ford specification WSS-M2C153-G and oil Filter-change.

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