Disassembly Ford Five Hundred I

Disassembly

Scheme 237

1. Remove the hydraulic lash adjusters.
2. Using the special tools, remove the keys, retainer and spring.
3. Remove the valve from the cylinder head.
4. Remove the valve stem seal.

Scheme 238

1. Using the special tool, install the valve stem seal.
2. Install the valve.
3. Using the special tools, install the valve spring, retainer and key.
4. Install the hydraulic lash adjusters.

SPECIAL TOOL SPECIFICATION Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Strap Wrench 303-D055 (D85L-6000-A) Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) Protector, Camshaft Oil Seal 303-463 (T94P-6256-AH) Installer, Camshaft Pulley 303-458 (T94P-6312-AH3) Installer, Camshaft Oil Seal 303-1139 Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A) Lifting Brackets, Engine 134-00243 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Scheme 239

ITEM SPECIFICATION

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

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Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

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Scheme 264

Scheme 265

Scheme 266

1. If removed, install the crankshaft key into the keyway on the crankshaft.
2. Install the oil separator cover, a new gasket and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Install the power steering pump bracket and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
4. Position the new gaskets and the LH and RH cylinder heads. 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.
5. Install the crankshaft damper bolt and rotate the crankshaft key way to the 11 o'clock position to locate top dead center (TDC).
6. Apply clean engine oil to the LH and RH camshaft roller followers.
7. Install the LH and RH camshaft roller followers.
8. Apply clean engine oil to the LH and RH camshafts.
9. Install the LH and RH camshafts. Locate the camshafts as shown.
10. Lubricate the camshaft journal caps with clean engine oil. Position the LH camshaft caps and install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
11. Position the RH camshaft caps and install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
12. Install the camshaft oil seal retainer and the 3 bolts. Tighten to 10 Nm (89 lb-in).
13. Position the new camshaft oil seal on the special tool.
14. Position the special tool and the camshaft oil seal on the camshaft.
15. Using the special tools, install the camshaft oil seal.
16. Remove the crankshaft damper bolt.
17. Install the crankshaft sprocket with the timing marks facing outward.
18. Position the chain tensioner in a soft-jawed vise.
19. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
20. Slowly compress the timing chain tensioner.
21. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
22. 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. 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.
23. Verify that the LH camshafts are correctly positioned.
24. Position the LH timing chain and guide and install the 2 bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
25. Install the LH timing chain tensioner arm and the LH timing chain tensioner. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
26. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
27. Verify that the RH camshafts are correctly positioned.
28. Install the RH timing chain and chain guide and install the 2 bolts. Tighten to 25 Nm (18 lb-ft). Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
29. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
30. Remove the LH and RH timing chain tensioner piston retaining wires.
31. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
32. Verify the timing with the following steps. There should be 12 chain links between the 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.
33. Remove the crankshaft damper bolt.
34. Install the ignition pulse wheel.
35. Install the LH and RH spark plugs. Tighten to 15 Nm (11 lb-ft).
36. Install 3 new gaskets in the engine front cover.
37. 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.
38. Position the engine front cover. Install the 14 bolts and the stud bolt. Tighten in the sequence shown to 25 Nm (18 lb-ft).
39. Install the belt tensioner and the bolt. Tighten to 45 Nm (33 lb-ft).
40. Using the special tool, install a new crankshaft front seal.
41. Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.
42. Using the special tools, install the crankshaft pulley.
43. Using the special tool to hold the crankshaft pulley, install the bolt and washer and tighten 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).
44. If equipped, install the block heater. Tighten to 14 Nm (10 lb-ft).
45. Install the oil pressure sender. Tighten to 14 Nm (10 lb-ft).
46. Install the oil pan baffle and the 8 nuts. Tighten the M8 nuts to 15 Nm (11 lb-ft) and then rotate 45 degrees. Tighten the M6 nuts to 5 Nm (44 lb-in) and then rotate 45 degrees.
47. Position the oil pump screen and pickup tube and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
48. Install the radio interference capacitor and the bolt. Tighten to 8 Nm (71 lb-in).
49. Install the coolant bypass tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
50. Install the coolant pump and the 4 bolts. Tighten in 4 stages: Stage 1: Tighten the coolant pump center bolt to 4 Nm (35 lb-in). Stage 2: Loosely install the 3 coolant pump outer bolts. Stage 3: Tighten the coolant pump center bolt to 25 Nm (18 lb-ft). Stage 4: Tighten the 3 coolant pump outer bolts to 10 Nm (89 lb-in).
51. Install the thermostat housing and the 2 bolts. Tighten to 10 Nm (89 lb-in).
52. Clean the LH and RH valve cover sealing surfaces.
53. Apply a 5 mm (0.19 in) dot of silicone gasket sealant to the front cover-to-RH cylinder head joints.
54. Position the RH valve cover. Install the 9 bolts and 5 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
55. Apply a 5 mm (0.19 in) dot of silicone gasket sealant to the front cover-to-LH cylinder head joints.
56. Position the LH valve cover. Install the 6 bolts and 8 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
57. Install the RH and LH ignition coils and the 6 bolts. Tighten to 6 Nm (53 lb-in).
58. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
59. Position a new gasket and the LH exhaust manifold and converter. Install the 6 new nuts. Tighten to 20 Nm (15 lb-ft).
60. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
61. Position a new gasket and the RH exhaust manifold and converter. Install the 6 new nuts. Tighten to 20 Nm (15 lb-ft).
62. Install the RH engine insulator bracket and the 4 bolts. Tighten to 55 Nm (41 lb-ft).
63. Install the generator, nuts and the bolt. Tighten to 48 Nm (35 lb-ft).
64. Position the oil filter adapter and loosely install the bolts. Tighten in 3 stages: Stage 1: Tighten the M22 bolt to 25 Nm (18 lb-ft). Stage 2: Tighten the M8 bolt to 25 Nm (18 lb-ft). Stage 3: Tighten the M22 bolt to 155 Nm (111 lb-ft).
65. Install a new oil filter. Tighten to 16 Nm (12 lb-ft).
66. Install the oil level indicator tube and the stud bolt. Tighten to 9 Nm (80 lb-in).
67. Position the engine wiring harness.
68. Connect the bypass and the coolant pump hoses.
69. Connect the engine coolant temperature (ECT) sensor and the radio interference capacitor electrical connectors.
70. Connect the LH ignition coil electrical connectors and attach the wiring retainers.
71. Connect the crankshaft position sensor (CKP) electrical connector and attach the wiring retainer.
72. Attach the ground wire and install the nut. Tighten to 20 Nm (15 lb-ft).
73. Connect the generator wiring and install the nut. Attach the wiring retainer. Tighten to 8 Nm (71 lb-in).
74. Connect the RH ignition coil electrical connectors and attach the wiring retainers.
75. Position the wiring conduit on the valve cover studs and install the nut. Tighten to 6 Nm (53 lb-in).
76. Position the new gaskets and the upper and lower intake manifold. Install the bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
77. Position the power steering pump, reservoir bracket and tubes. Install the 3 nuts. Tighten to 25 Nm (18 lb-ft).
78. Install the power steering fluid reservoir bracket nut. Tighten to 9 Nm (80 lb-in).
79. Position the power steering fluid reservoir and install the 2 nuts. Tighten to 9 Nm (80 lb-in).
80. Position the power steering tube bracket and install the bolt. Tighten to 7 Nm (62 lb-in).
81. Position the power steering tube bracket and install the bolt. Tighten to 7 Nm (62 lb-in).
82. Connect the RH HO2S and attach the retainer.
83. Connect the fuel charging wiring harness electrical connector.
84. Connect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.
85. Install and connect the positive crankcase ventilation (PCV) tube.
86. Connect the throttle body coolant hose.
87. Connect the throttle body electrical connector.
88. Connect the exhaust gas recirculation (EGR) system module electrical connector.
89. Position the EGR system module tube. Tighten to 40 Nm (30 lb-ft).
90. Connect the camshaft position sensor (CMP) electrical connector, attach the wiring retainers and install the 2 wiring conduit nuts. Tighten to 6 Nm (53 lb-in).
91. Connect the oil pressure sensor electrical connector.
92. Connect the LH heated oxygen sensor (HO2S) electrical connector and attach the wiring retainer.
93. Install the A/C compressor bracket and the 5 bolts. Tighten to 25 Nm (18 lb-ft).
94. Install the A/C compressor, 2 nuts and 2 bolts. Tighten to 25 Nm (18 lb-ft).
95. If equipped, install the A/C compressor and the bolt. Tighten to 25 Nm (18 lb-ft).
96. If equipped, install the A/C compressor shield, 2 nuts and the bolt. Tighten to 25 Nm (18 lb-ft).
97. Connect the LH catalyst monitor sensor electrical connector and attach the wiring retainer.
98. Connect the A/C compressor electrical connector.
99. Rotate the tensioner counterclockwise and install the accessory drive belt.
100. If equipped, install the A/C compressor pulley shield and the 3 retainers.
101. Install the special tool to the RH cylinder head.
102. Install the special tool to the LH cylinder head.
103. Install the lower half of the special tool.
104. Install the upper half of the special tool.
105. Using the special tools and a suitable engine crane, remove the engine from the engine stand.
106. Using the special tools, install the crankshaft rear oil seal.
107. Install the flexplate and the 8 bolts. Tighten to 80 Nm (59 lb-ft).

SPECIAL TOOL SPECIFICATION Lifting Brackets, Engine 134-00243 or equivalent Powertrain Lift with Tilting Plate 014-00765 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Engine Lifting Bracket Set 303-1140

ITEM SPECIFICATION

Scheme 267

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Scheme 277

Scheme 278

1. Using the special tools and a suitable engine crane, align the engine with the transaxle.
2. Install the 4 transaxle-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
3. Install the 3 transaxle-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
4. Install the engine-to-transaxle bolt. Tighten to 40 Nm (30 lb-ft).
5. Position the knock sensor (KS), install the bolt and connect the electrical connector. Tighten to 20 Nm (15 lb-ft).
6. Attach the heat shield to the KS.
7. Using the special tools and a suitable engine crane, position the powertrain on the subframe.
8. Install the LH engine insulator upper nut. Tighten to 70 Nm (62 lb-ft).
9. Install the RH engine insulator upper nut. Tighten to 70 Nm (62 lb-ft).
10. Position the RH exhaust manifold heat shield and install the 3 bolts. Tighten to 11 Nm (8 lb-ft).
11. Install the front transaxle stabilizer bolt. Tighten to 40 Nm (30 lb-ft).
12. If equipped, install the upper power transfer unit (PTU) bracket and the bolts. Tighten to 55 Nm (41 lb-ft).
13. Clean the 3 rear transaxle insulator bracket bolts using a wire brush and apply new threadlock to the threads.
14. Install the 3 rear transaxle insulator bracket bolts. Tighten to 55 Nm (41 lb-ft).
15. Position the ground cable and install the bolt. Tighten to 12 Nm (9 lb-ft).
16. Position the starter motor and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
17. Position the starter motor wiring and install the nuts. Tighten the larger nut to 12 Nm (9 lb-ft). Tighten the smaller nut to 9 Nm (80 lb-in).
18. Install the starter motor terminal cover.
19. Clean the 2 roll restrictor bolts using a wire brush and apply new threadlock to the threads.
20. Position the roll restrictor and install the 2 bolts. Tighten to 55 Nm (41 lb-ft).
21. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
22. Position the roll restrictor bracket and install the 4 bolts. Tighten to 55 Nm (41 lb-ft).
23. Connect the transmission control unit (TCU) wire harness.
24. Clean the 4 rear transaxle insulator bolts using a wire brush and apply new threadlock to the threads.
25. Install the 4 rear transaxle insulator bracket bolts. Tighten to 55 Nm (41 lb-ft).
26. Position the ground cable and install the bolt. Tighten to 12 Nm (9 lb-ft).
27. Position the starter motor and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
28. Position the starter motor wiring and install the nuts. Tighten the larger nut to 12 Nm (9 lb-ft). Tighten the smaller nut to 9 Nm (80 lb-in).
29. Install the starter motor terminal cover.
30. Clean the 2 roll restrictor bolts using a wire brush and apply new threadlock to the threads.
31. Position the roll restrictor and install the 2 bolts. Tighten to 55 Nm (41 lb-ft).
32. Attach the wiring harness to the roll restrictor.
33. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
34. Position the roll restrictor bracket and install the 4 bolts. Tighten to 55 Nm (41 lb-ft).
35. Attach the lower wiring harness retainers to the transaxle.
36. Attach the wiring harness retainers to the transaxle.
37. Attach the wiring harness retainer to the transaxle.
38. Connect the transaxle bulkhead electrical connector.
39. Attach the pin-type retainers to the subframe and connect the RH catalyst monitor sensor electrical connector.
40. Connect the power steering fluid tubes and install the bolt. Tighten to 25 Nm (18 lb-ft).
41. Install the power steering pressure (PSP) tube bracket bolt and connect the PSP switch electrical connector. Tighten to 25 Nm (18 lb-ft).
42. Using the special tool, position the powertrain and subframe in the vehicle.
43. Install the 2 forward subframe bolts and washers. Tighten to 200 Nm (148 lb-ft).
44. Position the rear subframe brackets and install the 6 bolts. Tighten the 2 larger bolts to 150 Nm (111 lb-ft). Tighten the 4 smaller bolts to 55 Nm (41 lb-ft).
45. Attach the steering column intermediate shaft and install a new bolt. Tighten to 25 Nm (18 lb-ft).
46. Attach the outer tie rods to the wheel knuckles and install new nuts. Tighten to 115 Nm (85 lb-ft).
47. Attach the stabilizer bar links to the struts and install new nuts. Tighten to 55 Nm (41 lb-ft).
48. If equipped, connect the driveshaft and install the bolts. Tighten to 25 Nm (18 lb-ft).
49. If equipped, position the driveshaft support bracket and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
50. Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated.
51. Position the oil pan and a new gasket. Loosely install the 15 bolts.
52. Position the LH catalytic converter bracket and install the 3 engine-to-transaxle bolts. Tighten to 40 Nm (30 lb-ft).
53. Tighten the 15 oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
54. Install the oil filter adapter-to-oil pan bolt. Tighten to 40 Nm (30 lb-ft) and then tighten an additional 90 degrees.
55. Install the 4 new torque converter nuts. Tighten to 36 Nm (27 lb-ft).
56. Position the lower torque converter access plug and install the pin-type retainers.
57. If equipped, connect the block heater electrical connector and attach the wiring retainers.
58. Connect the power steering cooler hose.
59. Connect the transmission cooler hoses.
60. Position the A/C tube and install the nut. Tighten to 8 Nm (71 lb-in).
61. Position the A/C manifold assembly tubes and install the bolt. Tighten to 20 Nm (15 lb-ft).
62. Connect the A/C high-pressure switch electrical connector.
63. Connect the 10-pin electrical connector and attach the wiring retainers.
64. Position the coolant tube and secure the tube in the clips.
65. Connect the coolant hoses to the thermostat housing.
66. Connect the brake booster vacuum hose to the upper intake manifold.
67. Connect the heater hose and the throttle body coolant hose.
68. Position the shift cable bracket and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
69. Connect the 16-pin electrical connector and attach the wiring retainer. Connect the electrical connector to the shift cable bracket.
70. Connect the shift cable.
71. Position the shift cable bracket and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
72. Connect the 16-pin electrical connector and attach the wiring retainers. Attach the electrical connector to the shift cable bracket.
73. Connect the shift cable.
74. Attach the B+ terminal to the battery cable and install the nut. Tighten to 5 Nm (44 lb-in).
75. Position the ground wire on the LH fender and install the bolt. Tighten to 10 Nm (89 lb-in).
76. Connect the power steering reservoir hose and attach the retainer.
77. Connect the 2 powertrain control module (PCM) electrical connectors and attach the wiring conduit.
78. Connect the vapor tube to the purge valve.
79. Connect the fuel tube to the fuel rail. Connect the fuel tube redundant clip.
80. Attach the fuel tube retainer to the upper intake manifold.
81. Position the ground strap on the RH fender and install the bolt. Tighten to 10 Nm (89 lb-in).
82. Clean the 4 roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
83. Position the roll restrictor cross brace and install the 4 new bolts. Tighten to 55 Nm (41 lb-ft).
84. Clean the roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
85. Install a new roll restrictor cross brace-to-roll restrictor bolt. Tighten to 48 Nm (35 lb-ft).
86. Install the LH and RH half shafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
87. Install the exhaust flex pipe and the LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/five-hundred/i-2004-2007/remont/exhaust/#exhaust-system) .
88. Install the cowl vent screen. For additional information, refer to «WIPERS AND WASHERS»(/ford/five-hundred/i-2004-2007/remont/wiperwasher-systems/#wiper-system-washer-system) .
89. Install the air cleaner outlet pipe and air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
90. Fill the engine with clean engine oil.
91. Connect the negative and positive battery cables. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
92. Evacuate and recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/automatic-hvac-system/#hvac-control-system-general-information) .
93. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#steering-system-general-information) .
94. Fill and bleed the cooling system. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine-system-general-information) .

See also:
• ENGINE SYSTEM-GENERAL INFORMATION
• INTRODUCTION - GASOLINE
• ENGINE COOLING
• BATTERY, MOUNTING AND CABLES
• INTAKE AIR DISTRIBUTION & FILTERING
• FUEL SYSTEM-GENERAL INFORMATION
• ENGINE IGNITION
• JACKING & LIFTING
• ACCESSORY DRIVE
• AUTOMATIC TRANSAXLE/TRANSMISSION - CVT
• AUTOMATIC TRANSAXLE - 6 SPEED
• EXHAUST SYSTEM
• FRONT END BODY PANELS
• FRONT DRIVE HALFSHAFTS
• CLIMATE CONTROL SYSTEM-GENERAL INFORMATION
• WIPERS AND WASHERS
• STEERING SYSTEM-GENERAL INFORMATION
• UPPER INTAKE MANIFOLD