Engine - 3.0L (4V): Other Ford Escape I

Material

MATERIAL SPECIFICATION

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1. Disconnect the fuel hose spring lock coupling.
2. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-204613-S12943095712005111200000) .
3. Disconnect the fuel rail. Disconnect the six fuel injector electrical connectors and wire harness locators. Disconnect the fuel pressure damper vacuum hose. Release the wire harness retainers from the fuel injection supply manifold.
4. Remove the bolts and the lower intake manifold. Remove and discard the gaskets.

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1. Clean and inspect all mating surfaces.
2. Install new gaskets in the lower intake manifold.
3. Install the lower intake manifold assembly and tighten the bolts in the sequence shown.
4. Connect the fuel rail. Position the wire harness locators and connect the six fuel injector electrical connectors. Connect the fuel pressure damper vacuum hose. Connect the fuel injection harness to the fuel supply manifold.
5. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-204613-S12943095712005111200000) .
6. Connect the fuel hose spring lock coupling.

MATERIAL SPECIFICATION

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1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
3. Remove the RH and LH valve covers. For additional information, refer to «VALVE COVER LH»(ref-204613-S27429627872005111200000) and «VALVE COVER RH»(ref-204613-S37859176532005111200000) .
4. Remove the right lower splash shield screws and the pin-type retainer.
5. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
6. Remove the nut and position the bracket and wiring harness aside.
7. Remove the upper generator mounting bolts.
8. Remove the lower generator bolts and position the generator aside.
9. Remove the generator mounting bracket bolts and remove the bracket.
10. Remove the bolt and the camshaft position (CMP) sensor.
11. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-204590) .
12. Remove the bolt and remove the belt tensioner.
13. Remove the crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT OIL SEAL»(ref-204613-S16922465532005111200000) .
14. Remove the crankshaft position (CKP) sensor. Disconnect the electrical connector. Remove the bolt and the sensor.
15. Remove the 2 oil pan-to-front cover bolts.
16. Remove the bolts, studs and the engine front cover. Remove and discard the front cover gaskets.

MATERIAL SPECIFICATION

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1. Remove the three nuts and the engine appearance cover.
2. Disconnect the crankcase ventilation tube from the valve cover.
3. Remove the three LH coil-on-plugs. Disconnect the electrical connectors. Remove the bolts. Remove the coils.
4. Disconnect the wiring harness from the valve cover studs.
5. Remove the engine lift bracket.
6. Position the power steering hose aside. Remove the bolt.
7. Remove the bolts, studs and the LH valve cover. Remove and discard the gasket.

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1. Install a new gasket on the valve cover.
2. Apply a 5-mm dot of silicone gasket sealant to the front cover to cylinder head joints.
3. Position the valve cover and install the studs and the bolts in the sequence shown.
4. Position the power steering hose and install the bolt.
5. Position the engine lift bracket and install the bolt.
6. Connect the wiring harness to the valve cover studs.
7. Install the three LH coil-on-plugs. Position the coils. Install the bolts. Connect the electrical connectors.
8. Connect the crankcase ventilation tube to the valve cover.
9. Install the engine appearance cover.

MATERIAL SPECIFICATION

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1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-204613-S12943095712005111200000) .
2. Remove the three RH coil-on-plugs. Disconnect the electrical connectors. Remove the bolts. Remove the coils.
3. Remove the wiring harness nuts and disconnect the oxygen sensor electrical connectors.
4. Remove the radio ignition interference capacitor.
5. Separate the harness from the center locating pins and position aside.
6. Disconnect the crankcase ventilation tube from the valve cover.
7. Remove the bolts, studs and the RH valve cover. Remove and discard the gasket.

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1. Install a new valve cover gasket.
2. Apply a 5-mm dot of silicone gasket sealant to the front cover to cylinder head joints.
3. Position the valve cover and install the bolt and the studs in the sequence shown.
4. Connect the crankcase ventilation tube to the valve cover.
5. Connect the radio ignition interference capacitor.
6. Connect the O2 sensor electrical connectors and wiring harness to the RH valve cover stud.
7. Install the three RH coil-on-plugs. Position the coils. Install the bolts. Connect the electrical connectors.
8. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-204613-S12943095712005111200000) .

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1. Remove the water pump belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
2. Using the special tools, remove the water pump drive pulley.
3. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204613-S28813170692005111200000) .
4. Using the special tools, remove the camshaft oil seal.
5. Remove the bolts and the camshaft oil seal retainer.
6. Loosen the LH camshaft cap bolts in sequence to allow the camshafts to rise from the cylinder head and remove the caps.
7. Remove the camshafts.

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1. Lubricate camshafts with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSS-M2C153-H and carefully position the camshafts into the cylinder head. Align the camshafts as shown. see scheme 91
2. Lubricate the bearing surfaces of the camshaft bearing caps with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H. Install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specifications WSS-M2C153-H. Install the bearing thrust caps and loosely install the bolts.
4. Tighten the bolts in the sequence shown.
5. Install a new camshaft oil seal retainer and a new gasket. Install a new gasket.
6. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204613-S28813170692005111200000).
7. Using special tools, install a new camshaft oil seal.
8. Using the special tool, install the water pump drive pulley.
9. Install the water pump belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084).

MATERIAL SPECIFICATION

Scheme 331

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204613-S28813170692005111200000) .
2. Loosen the RH camshaft cap bolts evenly in the sequence shown to allow the camshafts to rise from the cylinder head and remove the caps.
3. Remove the camshafts.

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1. Lubricate camshafts with clean engine oil and carefully position the camshafts into the cylinder head. Align the camshafts as shown.
2. Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil and install the bearing caps and loosely install the bolts.
3. Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil. Install the bearing thrust caps and loosely install the bolts.
4. Tighten the bolts in the sequence shown.
5. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204613-S28813170692005111200000) .

MATERIAL SPECIFICATION

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1. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER LH»(ref-204613-S27429627872005111200000) and «VALVE COVER RH»(ref-204613-S37859176532005111200000) .
2. Remove the LH and RH spark plugs.
3. Remove the RH front wheel.
4. Remove the splash shield.
5. Rotate the crankshaft until the camshaft lobe is pointing directly away from the follower.
6. Using the special tool, remove the followers.
7. To install, reverse the removal procedure. Lubricate the camshaft followers with clean engine oil.

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

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1. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
2. Remove the splash shield.
3. Install the special tool.
4. Remove the crankshaft pulley bolt and washer.
5. Using the special tool, remove the crankshaft pulley.

Scheme 341

1. Apply silicone gasket and sealant to the end of the keyway slot.
2. Using the special tool, install the crankshaft pulley.
3. Install the bolt and the washer and tighten in four stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Install RH front inner splash shield.
5. Install the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .

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MATERIAL SPECIFICATION

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1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204613-S09792329092005111200000) .
2. Using the special tool, remove the crankshaft front oil seal and discard.

Scheme 344

1. Apply clean engine oil to the seal before installing the seal.
2. Using the special tool, install the crankshaft front oil seal.
3. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204613-S09792329092005111200000) .

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1. Remove the roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204613-S37592917832005111200000) .
2. Pressurize the cylinder using compressed air.
3. Using the special tool, remove the key, retainer, and valve spring.
4. To install, reverse the removal procedure.

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MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

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1. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-204613-S42126637972005111200000) .
2. Remove the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(ref-204619) .
3. Remove the LH camshafts. For additional information, refer to «CAMSHAFTS LH»(ref-204613-S33275645482005111200000) .
4. Remove the camshaft followers.
5. Remove the hydraulic lash adjusters.
6. Position the water pump and housing aside. For additional information, refer to «ENGINE COOLING»(ref-204619) .
7. Raise and support the vehicle on a hoist.
8. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD LH»(ref-204613-S30808746032005111200000) .
9. Remove the oil level indicator tube stud bolt.
10. Lower the vehicle.
11. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.
12. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) deep.

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1. Position the LH cylinder head and gasket and install the bolts. Tighten the bolts in six stages, in the sequence shown: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten bolts 90 degrees. 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.
2. Install the water pump. For additional information, refer to «ENGINE COOLING»(ref-204619) .
3. Raise the vehicle.
4. Install the stud bolt.
5. Install the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD LH»(ref-204613-S30808746032005111200000) .
6. Lower the vehicle.
7. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
8. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil.
9. Install the LH camshafts. For additional information, refer to «CAMSHAFTS LH»(ref-204613-S33275645482005111200000) .
10. Install the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(ref-204619) .
11. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-204613-S42126637972005111200000) .

MATERIAL SPECIFICATION

Scheme 352

1. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-204613-S42126637972005111200000) .
2. Remove the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(ref-204619) .
3. Remove the exhaust gas recirculation (EGR) tube. .
4. Remove the RH camshafts. For additional information, refer to «CAMSHAFTS RH»(ref-204613-S09586164752005111200000) .
5. Remove the camshaft followers.
6. Remove the hydraulic lash adjusters.
7. Raise and support the vehicle on a hoist. .
8. Remove the six nuts from the RH exhaust manifold.
9. Lower the vehicle.
10. Remove the bolts in the sequence shown and remove the cylinder head. Discard the gasket and the bolts.
11. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) deep.

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1. Position the RH cylinder head and gasket and install the bolts. Tighten the bolts in six stages, in the sequence shown: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten bolts 90 degrees. 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.
2. Raise the vehicle on a hoist. .
3. Install RH exhaust manifold nuts in the sequence shown.
4. Lower the vehicle.
5. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil.
6. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil.
7. Install the RH camshafts. For additional information, refer to «CAMSHAFTS RH»(ref-204613-S09586164752005111200000) .
8. Install the coolant bypass tube. For additional information, refer to «ENGINE COOLING»(ref-204619) .
9. Install the exhaust gas recirculation (EGR) tube. .
10. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-204613-S42126637972005111200000) .

MATERIAL SPECIFICATION

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1. Drain the engine coolant. For additional information refer to «ENGINE COOLING»(ref-204619) .
2. Remove the oil pan drain bolt and drain the engine oil.
3. Remove and discard the oil filter.
4. Disconnect the coolant hoses at the cooler.
5. Remove and discard the oil cooler.
6. To install, reverse the removal procedure. Install a new oil cooler. Fill the crankcase with clean engine oil.

Scheme 360

1. Raise and support the vehicle. .
2. Remove the right side splash shield.
3. Remove the oil pressure sender. Disconnect the electrical connector. Remove the sender.
4. To install, reverse the removal procedure.

MATERIAL SPECIFICATION

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1. Release the push-pin securing the top radiator hose to the radiator core support and position the hose aside.
2. Remove the oil level indicator.
3. Remove the oil level indicator tube. Remove the stud bolt. Remove the oil level indicator tube from the engine.
4. Remove the oil level indicator tube from the vehicle by guiding it between the radiator core support and the front grille.
5. To install, reverse the removal procedure. Install a new O-ring seal and lubricate with clean engine oil.

MATERIAL SPECIFICATION

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1. Remove the flexible exhaust pipe. .
2. Disconnect the downstream catalyst monitor sensor.
3. Drain the oil.
4. Install the drain plug.
5. Remove and discard the oil filter.
6. Remove the 15 bolts.
7. Remove the three bolts and the oil pan.

MATERIAL SPECIFICATION

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1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-204613-S26465898942005111200000) .
2. Remove the nut, bolts and the oil pump screen and pickup tube.
3. Remove and discard the O-ring seal.

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1. Install a new O-ring seal and lubricate with clean engine oil.
2. Install the oil pump screen and pickup tube. Position the oil pump screen and pickup tube. Install the bolts. Install the nut. Tighten the nut in two stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten 45 degrees.
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-204613-S26465898942005111200000) .

Scheme 372

1. Remove the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-204613-S12067926902005111200000) .
2. Remove the nuts and the oil pan baffle.

Scheme 373

1. Position the oil pan baffle and install the nuts. Tighten the nuts in two stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten 45 degrees.
2. Install the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-204613-S12067926902005111200000) .

Scheme 374

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204613-S28813170692005111200000) .
2. Remove the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-204613-S12067926902005111200000) .
3. Remove the bolts in the indicated sequence and remove the oil pump.

Scheme 375

1. Position the oil pump and install the bolts in the sequence shown.
2. Install the oil pump screen cover and tube. For additional information, refer to «OIL PUMP SCREEN AND PICKUP TUBE»(ref-204613-S12067926902005111200000) .
3. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204613-S28813170692005111200000) .

Scheme 376

1. Remove the transaxle. For additional information, refer to «REMOVAL & INSTALLATION - A/T»(ref-155795) .
2. Remove the bolts and the flexplate.
3. To install, reverse the removal procedure.

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MATERIAL SPECIFICATION

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1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-204613-S42198822162005111200000) .
2. Using the special tools, remove the crankshaft rear oil seal and discard.

MATERIAL SPECIFICATION

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1. Remove the top compression ring.
2. Remove the second compression ring.
3. Remove the first oil control ring.
4. Remove the oil control spacer ring.
5. Remove the second oil control ring.
6. Remove the clips.
7. Remove the piston pin and the connecting rod from the piston.
8. Clean and inspect the connecting rod and the piston. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-204610) for basic mechanical concerns.

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1. Lubricate the piston pin and piston bore with clean engine oil and install the piston pin.
2. Install the clips.
3. Check the piston ring end gap. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-204610) for basic mechanical concerns.
4. Lubricate the piston rings with clean engine oil.
5. Install the first oil control ring.
6. Install the oil control spacer ring.
7. Install the second oil control ring.
8. Install the second compression ring. The top of the second compression ring has a "0" on it. Position this side of the ring towards the top of the piston.
9. Install the top compression ring. The top compression ring can be installed with either side up.

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1. Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.
2. If removed, install the crankshaft key into the keyway on the crankshaft.
3. Select the crankshaft main bearings for each crankshaft journal. Read the code on the crankshaft flange. Read the code on the cylinder block rear face. The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2. The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.
4. 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 *8480*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 84 crankshaft row. Mains 2,3 and 4 should all be grade 2.
5. Install the main bearings into the cylinder block.
6. Install the main bearings into the lower cylinder block.
7. Install the crankshaft thrust bearing.
8. Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the cylinder block as shown.
9. Apply Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-H to the crankshaft main and rod bearing journals.
10. Position the crankshaft in the cylinder block.
11. Position the lower cylinder block and install the bolts and studs in the sequence shown in four stages. Stage 1: Tighten fasteners 1-8 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 9-16 to 40 Nm (30 lb-ft). Stage 3: Tighten fasteners 1-16 90 degrees. Stage 4: Tighten fasteners 17-22 to 25 Nm (18 lb-ft).
12. Using the special tool, measure the crankshaft end play.
13. Using the special tool, install the crankshaft rear oil seal.
14. Position the flexplate and install the bolts.
15. Mount the engine on an engine stand.
16. Apply Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-H to the cylinder bores.
17. Using the special tools, install the piston and connecting rod assemblies.
18. Check connecting rod bearing clearance. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-204610) for basic mechanical concerns.
19. Install the connecting rod caps and tighten the bolts in two stages. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft).
20. Position the oil pump and install the bolts in the indicated sequence.
21. Position the oil pan baffle. Install the nuts and tighten in two stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten 45 degrees.
22. Install a new O-ring seal on the oil pump screen and pick-up tube.
23. Install the oil pump screen and pick up tube. Position the oil pump screen and pick up tube. Install the bolts. Install the nut and tighten in two stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten 45 degrees.
24. Install the power steering/engine support bracket.
25. Install the oil separator. Install the two bolts.
26. Position the LH cylinder head and gasket and install the bolts. Tighten the bolts in six stages, in the sequence shown: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten bolts 90 degrees. 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.
27. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).
28. Apply Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-H to the LH and RH camshaft followers.
29. Install the LH and RH camshaft followers.
30. Apply Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-H to the LH and RH camshafts.
31. Install the LH and RH camshafts. Locate the camshafts as shown.
32. Position the LH camshaft caps and install the bolts in the sequence shown.
33. Position the RH camshaft caps and install the bolts in the sequence shown.
34. Remove the crankshaft damper bolt.
35. Install the crankshaft sprockets.
36. Position the chain tensioner in a soft-jawed vise.
37. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
38. Slowly compress the timing chain tensioner.
39. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
40. If the timing marks on the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and the RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to link 42 and mark the link.
41. Position the LH timing chain and guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
42. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the bolt.
43. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is at the 3 o'clock position.
44. Verify that the RH camshafts are correctly positioned.
45. Position the RH timing chain and chain guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
46. Install the RH timing chain tensioner arm and the RH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the bolts.
47. Remove the LH and the RH timing chain tensioner piston retaining wires.
48. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC). Verify the timing with the following steps: There should be 12 chain links between the front camshaft timing marks. There should be 27 chain links between the camshaft and the crankshaft timing marks. There should be 30 chain links between the camshaft and the crankshaft timing marks.
49. Remove the crankshaft damper bolt.
50. Install the ignition pulse wheel.
51. Install the special tool to hold the flexplate.
52. Install three gaskets in the front cover.
53. Apply a 6 mm (0.24 in) dot of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the cylinder block to lower cylinder block and cylinder head mating surfaces.
54. Position the front cover and install the bolts and studs in the sequence shown.
55. Using the special tool, install the crankshaft front oil seal.
56. Apply a 10 mm (0.24 in) dot of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the front cover to cylinder block mating surface.
57. Position the oil pan and gasket and loosely install the bolts and studs in the indicated sequence.
58. Align the transaxle face of the oil pan with the rear of the cylinder block. The pan should be 0.00 mm (0.0 in) - 0.25 mm (0.009 in) under flush. Assemblies that are between 0.26 (0.01 in) - 0.50 mm (0.019 in) should be shimmed using either one or two 0.25 mm (0.009 in) gold shims. Assemblies that are between 0.51 mm (0.20 in) - 0.75 mm (0.029 in) should be shimmed using either one or two 0.50 mm (0.019 in) silver shims. If the pan measures greater than 0.75 mm (0.029 in) or the pan is over flush of the cylinder block, the entire pan assembly must be removed and a new one installed.
59. Tighten the oil pan bolts and studs in the sequence shown.
60. Install a new seal on the oil level indicator tube.
61. Install the oil level indicator tube and install the bolt.
62. Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A to the end of the crankshaft damper keyway slot.
63. Using the special tool, install the crankshaft vibration damper.
64. Install the crankshaft vibration damper washer and tighten the bolt in four 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).
65. Install new gaskets in the valve covers.
66. Apply a 8 mm (0.31 in) dot of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A at the cylinder block to front cover mating surface of the LH and RH valve covers.
67. Position the RH valve cover and install the bolts and studs in the sequence shown.
68. Position the LH valve cover and install the bolts and studs in the sequence shown.
69. Install the spark plugs.
70. Apply a light film of Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford Specification ESE-M1C171-A to the interior of the spark plug boot prior to installation. Install the six coil-on-plugs and install the bolts.
71. Install new gaskets in the lower intake manifold.
72. Position the knock sensor and install the bolt.
73. Remove the special tool.
74. Position the coolant bypass tube and connect the hoses.
75. Install the oil pressure sender and the block heater.
76. Install the oil cooler.
77. Install the radio ignition noise suppressor electrical connector.
78. Install the generator support bracket.
79. Install the power steering pump.
80. Install the power steering pump pulley.
81. Install the oil filter.
82. Connect the coolant hoses at the oil cooler.
83. Install the water pump assembly.
84. Position a new gasket and tighten the exhaust manifold nuts in the sequence shown.
85. Install the engine lift bracket.
86. Position the gasket and install the lower intake manifold.
87. Position and connect the engine control sensor wiring in the locations shown. coils-on-plugs fuel injectors
88. Connect the radio interference capacitor.
89. Connect the crankshaft and camshaft position sensor electrical connectors.
90. Install new gaskets in the upper intake manifold.
91. Install the upper intake manifold.
92. Install and connect the engine control wire harness.
93. Connect the coolant temperature sender and the oil pressure switch.
94. Connect the vacuum line from the fuel pressure damper.
95. Connect the engine control sensor wiring to the upper intake manifold.
96. Connect the EGR vacuum regulator and the differential pressure feedback EGR electrical connectors.
97. Install the PCV tube.
98. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.

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1. Position the engine onto the subframe assembly.
2. Install the six bolts in the transaxle.
3. Using the special tools, position the powertrain on the universal powertrain lift and remove the special tools.
4. Using a bracket from a heavy duty engine stand, support the front of the engine.
5. Position the halfshaft bracket and install the bolts.
6. Install a new gasket and the RH exhaust manifold.
7. Install the generator.
8. Position the EGR tube and connect the fitting.
9. Connect the EGR tube nut at the manifold connector.
10. Connect the differential pressure feedback EGR sensor electrical connector.
11. Connect the heated oxygen sensor (HO2S) electrical connector and install a new tie-strap.
12. Connect the output shaft speed (OSS) sensor and turbine speed sensor (TSS) electrical connectors.
13. Connect the knock sensor jumper electrical connector.
14. Install the starter.
15. Install the bolt and connect the transaxle control harness to the bracket.
16. Connect the transaxle harness.
17. Connect the transmission range (TR) sensor.
18. Connect the heated oxygen sensors.
19. Position the powertrain in the vehicle.
20. Install the two bolts for the motor mount support.
21. Install the two subframe side nuts.
22. Install two rear subframe bolts.
23. Position the transaxle mount and install the bolts.
24. Connect the power steering return hose.
25. Install the motor mount bracket, the bolts and the nuts.
26. Remove the bracket.
27. Remove the universal powertrain lift.
28. Install the four bolts.
29. Install the four torque converter nuts.
30. Install the inspection plug.
31. Connect the two transmission cooler tubes.
32. Connect the steering shaft to the rack and install the bolt.
33. Connect the LH and RH struts to the steering knuckles and install the bolts.
34. Install the brake calipers to the steering knuckle.
35. If equipped, install the LH and RH wheel speed sensor harness brackets.
36. If equipped, position the LH and RH wheel speed sensors and install the bolts.
37. Connect the LH and RH sway bar links to the strut mount.
38. If equipped, install the intermediate driveshaft. For additional information, refer to «DRIVESHAFT»(ref-204573) .
39. Install both front wheel and tire assemblies. .
40. Install the A/C compressor and the bolts.
41. Remove the plugs and install the A/C manifold and tube assembly.
42. Connect the A/C clutch field coil electrical connector.
43. If equipped, connect the engine block heater electrical connector.
44. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
45. Install the flex pipe. .
46. Install the lower radiator air deflectors.
47. Lower the vehicle.
48. Install the oil level indicator.
49. Position the wire harness and install the wire harness locating retainers.
50. Connect the ground strap and the electrical connector.
51. Connect the power steering line. Install the bracket bolt. Connect the power steering pressure (PSP) switch electrical connector. Connect the power steering line.
52. Connect the power steering return line.
53. Connect the vacuum line at the vacuum reservoir check valve.
54. Connect the brake booster vacuum hose.
55. Connect the transaxle linkage.
56. Install the cables and the nuts.
57. Install the power distribution box cover.
58. Connect the connector to the power distribution box.
59. Position the thermostat housing and connect the hoses.
60. Connect the heater hose and install a new tie-strap.
61. Connect the ground wire.
62. Connect the powertrain control module (PCM) electrical connector.
63. Connect the vapor management valve (VMV) electrical connector.
64. Connect the accelerator cable and speed control actuator cable.
65. Connect the fuel line. .
66. Install the air cleaner outlet tube and air cleaner. .
67. Install the battery and the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
68. Install the water pump drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
69. Fill the crankcase with oil. SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSSM2C153-G.
70. Fill the engine cooling system. For additional information, refer «ENGINE COOLING»(ref-204619) .
71. Fill and purge the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-204578) .
72. Recharge the A/C system. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139311) .