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Section 461 (Engine - 2.3L): Assembly: Engine

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools
G03273832Courtesy of FORD MOTOR CO.
MATERIAL SPECIFICATIONS

Item Specification
Metal Surface Cleaner
F4AZ -19A536-RA or equivalent		 WSE-M5B392-A
Silicone Gasket and Sealant
F7AZ-19554-EA or equivalent		 WSE-M4G323-A4
MERPOL® ESE-M99B144-B
Super Premium SAE 5W-20 Motor Oil
XO-5W20-QSP or equivalent		 WSS-M2C153-H
Silicone Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A		 ESE-M1C171-A
Motorcraft Premium Gold Coolant VC-7-A (in Oregon YC-7-B, in Canada YC-7- C) WSS-M97B51-A1
High-Temperature 4x4 Front Axle and Wheel Bearing Grease
E8TZ-19590-A		 ESA-M1C198-A

    ALL VEHICLES 

    WARNING: Failure to position the No. 1 piston at top dead center TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  1. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
  2. Remove the plug bolt.
    Fig 2: Removing Plug Bolt
    G03273833Courtesy of FORD MOTOR CO.
    3. NOTE: Only turn the engine in the normal direction of rotation.
    NOTE: Installing the special tool in this step will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.
    Fig 3: Installing Special Tool In Plug Bolt Hole
    G03273834Courtesy of FORD MOTOR CO.
  3. Install the special tool.
    4. NOTE: Clean the sealing surface with metal surface cleaner.
  4. Install the oil pump assembly and bolts. Tighten the bolts in the sequence shown in two stages.
    1. Stage 1: Tighten the bolts to 10 N.m (89 lb-in).
    2. Stage 2: Tighten the bolts to 20 N.m (15 lb-ft).
      Fig 4: Oil Pump Bolts Tightening Sequence
      G03273835Courtesy of FORD MOTOR CO.
    5. NOTE: Clean the sealing surface with a metal surface cleaner.
    Fig 5: Installing Oil Pump Pickup Tube Gasket And Pickup Tube
    G03273836Courtesy of FORD MOTOR CO.
  5. Install a new oil pump pickup tube gasket and the pickup tube. Tighten the bolts in the sequence shown.
  6. Using the special tool, install the rear main oil seal.
    Fig 6: Installing Rear Main Oil Seal
    G03273837Courtesy of FORD MOTOR CO.
  7. Tighten the rear main oil seal bolts in the sequence shown.
    Fig 7: Rear Main Oil Seal Bolts Tightening Sequence
    G03273838Courtesy of FORD MOTOR CO.
    8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
    NOTE: Clean the mating surface with metal surface cleaner.
    NOTE: If the oil pan is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 8: Oil Pan Bolts Tightening Sequence
    G03273839Courtesy of FORD MOTOR CO.
  8. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the oil pan bolts in the sequence shown.
  9. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 9: Installing Cylinder Head Alignment Dowels
    G03273840Courtesy of FORD MOTOR CO.
    10. NOTE: Clean the gasket surface with metal surface cleaner.
    Fig 10: Applying Silicone Gasket And Sealant
    G03273841Courtesy of FORD MOTOR CO.
  10. Apply silicone gasket and sealant to the locations shown.
  11. Install a new cylinder head gasket.
  12. Clean the cylinder head gasket surface with metal surface cleaner.
    13. NOTE: The cylinder head must be secured within four minutes of silicone gasket application. If the cylinder head is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
    NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    NOTE: Lubricate the cylinder head bolts with clean engine oil.
  13. Install the cylinder head and the new bolts. Tighten the bolts in the sequence shown in five stages.
    • Stage 1: Tighten the bolts to 5 N.m (44 lb-in).
    • Stage 2: Tighten the bolts to 15 N.m (11 lb-ft).
    • Stage 3: Tighten the bolts to 45 N.m (33 lb-ft).
    • Stage 4: Tighten the bolts an additional 90 degrees (1/4 turn).
    • Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
      Fig 11: Cylinder Head Bolts Tightening Sequence
      G03273842Courtesy of FORD MOTOR CO.
    14. CAUTION: Install the camshafts with the alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  14. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
    • Stage 2: Tighten the bolts to 7 N.m (62 lb-in).
    • Stage 3: Tighten the bolts to 16 N.m (12 lb-ft).
      Fig 12: Camshaft Bearing Caps Tightening Sequence
      G03273843Courtesy of FORD MOTOR CO.
    15. CAUTION: The crankshaft, the crankshaft sprocket, and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. The diamond washers must be installed correctly, or severe engine damage can result.
  15. Install the washers and the oil pump chain and sprockets.
    • The crankshaft sprocket flange must be facing away from the engine block.
      Fig 13: Installing Washers And Oil Pump Chain And Sprockets
      G03273844Courtesy of FORD MOTOR CO.
    16. NOTE: The oil pump chain sprocket must be held in place.
    Fig 14: Tightening Oil Pump Sprocket Bolt
    G03273845Courtesy of FORD MOTOR CO.
  16. Tighten the oil pump sprocket bolt.
  17. Install the oil pump chain guide and the shoulder bolt.
    Fig 15: Installing Oil Pump Chain Guide And Shoulder Bolt
    G03273846Courtesy of FORD MOTOR CO.
  18. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
    Fig 16: Installing Oil Pump Chain Tensioner
    G03273847Courtesy of FORD MOTOR CO.
    19. NOTE: Sprockets must turn freely on the camshafts.
    Fig 17: Installing Camshaft Sprockets
    G03273848Courtesy of FORD MOTOR CO.
  19. Install the camshaft sprockets and the bolts. Do not tighten the sprocket bolts at this time.
    20. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    Fig 18: Compressing Timing Chain Tensioner Plunger
    G03273849Courtesy of FORD MOTOR CO.
  20. Using the edge of a vise, compress the timing chain tensioner plunger.
  21. Using a small pick, push back and hold the ratchet mechanism.
    Fig 19: Holding Ratchet Mechanism
    G03273850Courtesy of FORD MOTOR CO.
  22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 20: Pushing Ratchet Arm Back Into Tensioner Housing
    G03273851Courtesy of FORD MOTOR CO.
  23. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 21: Installing A Paper Clip Into Hole In Tensioner Housing
    G03273852Courtesy of FORD MOTOR CO.
  24. Install the timing chain.
    Fig 22: Installing Timing Chain
    G03273853Courtesy of FORD MOTOR CO.
  25. Install the timing chain guides.
    Fig 23: Installing Timing Chain Guides
    G03273854Courtesy of FORD MOTOR CO.
  26. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.
    Fig 24: Installing Timing Chain Tensioner
    G03273855Courtesy of FORD MOTOR CO.
    27. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    Fig 25: Installing Special Tool In Timing Slots On Rear Of Both Camshafts
    G03273856Courtesy of FORD MOTOR CO.
  27. Install the special tool in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
    28. NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.
    Fig 26: Tightening Camshaft Sprocket Bolts
    G03273857Courtesy of FORD MOTOR CO.
  28. Tighten the camshaft sprocket bolts.
  29. Clean the front cover gasket surface with metal surface cleaner.
  30. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
    Fig 27: Applying Bead Sealant To Front Cover
    G03273858Courtesy of FORD MOTOR CO.
  31. Apply silicone gasket and sealant to the locations shown.
    Fig 28: Applying Silicone Sealant
    G03273859Courtesy of FORD MOTOR CO.
    32. NOTE: The front cover must be secured within four minutes of silicone gasket application. If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
  32. Install the front cover. Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Tighten the 8 mm bolts to 10 N.m (89 lb-in).
    • Stage 2: Tighten the 10 mm bolts to 25 N.m (18 lb-ft).
    • Stage 3: Tighten the 13 mm bolts to 48 N.m (35 lb-ft).
      Fig 29: Front Cover Bolts Tightening Sequence
      G03273860Courtesy of FORD MOTOR CO.
    33. NOTE: Do not reuse the crankshaft pulley bolt.
    NOTE: Apply clean engine oil on the seal area before installing.
    Fig 30: Installing Crankshaft Pulley
    G03273861Courtesy of FORD MOTOR CO.
  33. Install the crankshaft pulley and hand-tighten the bolt.
    34. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
  34. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
    • Rotate the crankshaft pulley as necessary to align the bolt holes.
      Fig 31: Rotating Crankshaft Pulley To Align Bolt Holes
      G03273862Courtesy of FORD MOTOR CO.
    35. CAUTION: Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
  35. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages.
    • Stage 1: Tighten to 100 N.m (74 lb-ft).
    • Stage 2: Rotate an additional 90 degrees (1/4 turn).
      Fig 32: Tightening Crankshaft Pulley Bolt
      G03273863Courtesy of FORD MOTOR CO.
  36. Remove the special tools.
    Fig 33: Removing Special Tool From Crankshaft Pulley
    G03273864Courtesy of FORD MOTOR CO.
  37. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 34: Removing Bolt From Crankshaft Pulley
    G03273865Courtesy of FORD MOTOR CO.
  38. Remove the special tool.
    Fig 35: Removing Special Tool From Plug Bolt Hole
    G03273866Courtesy of FORD MOTOR CO.
  39. Remove the special tool.
    Fig 36: Removing Special Tool From Camshafts
    G03273867Courtesy of FORD MOTOR CO.
    40. NOTE: Only turn the engine in the normal direction of rotation.
  40. Turn the engine two complete revolutions.
    41. NOTE: Only turn the engine in the normal direction of rotation.
  41. Turn the engine until the No. 1 piston is at top dead center (TDC).
  42. Install the special tool.
    Fig 37: Installing Special Tool In Plug Bolt Hole
    G03273868Courtesy of FORD MOTOR CO.
    43. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
  43. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, correct the engine timing.
      Fig 38: Checking Position Of Crankshaft Pulley
      G03273869Courtesy of FORD MOTOR CO.
  44. Using the special tool, check the position of the camshafts.
    • If it is not possible to install the special tool, correct the engine timing.
      Fig 39: Checking Position Of Camshafts
      G03273870Courtesy of FORD MOTOR CO.
  45. Remove the special tool.
    Fig 40: Removing Special Tool From Camshafts
    G03273871Courtesy of FORD MOTOR CO.
  46. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 41: Removing Bolt From Crankshaft Pulley
    G03273872Courtesy of FORD MOTOR CO.
  47. Remove the special tool.
    Fig 42: Removing Special Tool From Plug Bolt Hole
    G03273873Courtesy of FORD MOTOR CO.
  48. Install the plug bolt.
    Fig 43: Installing Plug Bolt
    G03273874Courtesy of FORD MOTOR CO.
    49. NOTE: The crankshaft position (CKP) sensor alignment tool is supplied with the new sensor and is not available separately.
    Fig 44: Installing New CKP Sensor
    G03273875Courtesy of FORD MOTOR CO.
  49. Using the special tool, install a new crankshaft position (CKP) sensor. The tool must engage a tooth of the vibration damper.
  50. Clean the valve cover gasket surface with metal surface cleaner.
  51. Apply silicone gasket and sealant to the locations shown.
    Fig 45: Applying Sealant
    G03273876Courtesy of FORD MOTOR CO.
    52. NOTE: The valve cover must be secured within four minutes of silicone gasket application. If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
    Fig 46: Installing Valve Cover
    G03273877Courtesy of FORD MOTOR CO.
  52. Install the valve cover.
  53. Install the following:
    • Camshaft position (CMP) sensor.
    • Cylinder head temperature (CHT) sensor.
    • Spark plugs.
      Fig 47: Installing CMP Sensor, CHT Sensor & Spark Plugs
      G03273878Courtesy of FORD MOTOR CO.
    54. NOTE: Clean the water pump gasket surface with metal surface cleaner.
    NOTE: Lubricate the water pump O-ring seal with clean engine coolant prior to assembly.
    Fig 48: Installing Coolant Pump
    G03273879Courtesy of FORD MOTOR CO.
  54. Install the coolant pump.
  55. Install the coolant pump pulley.
    Fig 49: Installing Coolant Pump Pulley
    G03273880Courtesy of FORD MOTOR CO.
  56. Install the fuel injection supply manifold and the ground strap.
    Fig 50: Installing Fuel Injection Supply Manifold & Ground Strap
    G03273881Courtesy of FORD MOTOR CO.
  57. Install the left motor mount.
    Fig 51: Installing Left Motor Mount
    G03273882Courtesy of FORD MOTOR CO.
    58. NOTE: The knock sensor must not touch the engine vent cover.
    Fig 52: Installing Engine Vent Cover And Knock Sensor
    G03273883Courtesy of FORD MOTOR CO.
  58. Install the engine vent cover and the knock sensor (KS).
    59. NOTE: Clean the thermostat housing gasket surface with metal surface cleaner.
    Fig 53: Installing New Gasket And Thermostat Housing
    G03273884Courtesy of FORD MOTOR CO.
  59. Install a new gasket and the thermostat housing.
  60. Install the ignition coil.
    Fig 54: Installing Ignition Coil
    G03273885Courtesy of FORD MOTOR CO.
    61. NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.
  61. Connect the spark plug wires to the spark plugs.
  62. Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.
    Fig 55: Attaching Fuel Charging Wiring Harness To Valve Cover Studs
    G03273886Courtesy of FORD MOTOR CO.
  63. Connect the ignition coil and the CHT sensor electrical connectors.
    Fig 56: Connecting Ignition Coil & CHT Sensor
    G03273887Courtesy of FORD MOTOR CO.
  64. Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.
    Fig 57: Connecting Fuel Injector Connectors & Wiring Harness
    G03273888Courtesy of FORD MOTOR CO.
  65. Install the intake manifold.
    Fig 58: Installing Intake Manifold
    G03273889Courtesy of FORD MOTOR CO.
  66. Secure the fuel hose clip to the intake manifold.
    Fig 59: Securing Fuel Hose Clip To Intake Manifold
    G03273890Courtesy of FORD MOTOR CO.
  67. Install the exhaust gas recirculation (EGR) tube.
    • Install the EGR tube bracket to the intake manifold.
    • Connect the EGR tube to the cylinder head.
      Fig 60: Installing EGR Tube
      G03273891Courtesy of FORD MOTOR CO.
  68. Connect the EGR tube to the intake manifold.
    Fig 61: Connecting EGR Tube To Intake Manifold
    G03273892Courtesy of FORD MOTOR CO.
  69. Attach the engine wiring harness pin-type retainers to the intake manifold.
  70. Connect the CMP sensor electrical connector and the PCV hose.
    Fig 62: Connecting CMP Sensor And PCV Hose
    G03273893Courtesy of FORD MOTOR CO.
  71. Install the engine wiring harness connector bracket and connect the knock sensor electrical connector.
    Fig 63: Installing Engine Wiring Harness Connector Bracket & Connecting KS
    G03273894Courtesy of FORD MOTOR CO.
  72. Connect the CKP sensor and wiring pin-type retainers.
    Fig 64: Connecting CKP Sensor
    G03273895Courtesy of FORD MOTOR CO.
  73. Connect the following electrical connectors:
    • Manifold absolute pressure (MAP) sensor.
    • Throttle position (TP) sensor.
    • Idle air control (IAC) valve.
      Fig 65: Connecting MAP Sensor, TP Sensor & IAC Valve
      G03273896Courtesy of FORD MOTOR CO.
  74. Install the power steering pump assembly.
    Fig 66: Installing Power Steering Pump Assembly
    G03273897Courtesy of FORD MOTOR CO.
    75. NOTE: Clean the EGR valve gasket surface with metal surface cleaner.
    Fig 67: Connecting EGR Electrical Connector And Coolant Hose
    G03273898Courtesy of FORD MOTOR CO.
  75. Install a new gasket and the EGR valve. Connect the EGR electrical connector and coolant hose.
    76. NOTE: Clean the rear coolant outlet pipe gasket surface with metal surface cleaner.
  76. Install a new gasket and the rear coolant outlet pipe.
    1. Tighten the bolts.
    2. Connect the coolant hose.
    3. Connect the engine coolant temperature sender unit electrical connector.
      Fig 68: Installing New Gasket And Rear Coolant Outlet Pipe
      G03273899Courtesy of FORD MOTOR CO.
  77. Install the block heater, if so equipped.
    Fig 69: Installing Block Heater
    G03273900Courtesy of FORD MOTOR CO.
  78. Install the gasket and the exhaust manifold.
    Fig 70: Installing Gasket And Exhaust Manifold
    G03273901Courtesy of FORD MOTOR CO.
  79. Install the coolant tube assembly.
    Fig 71: Installing Coolant Tube Assembly
    G03273902Courtesy of FORD MOTOR CO.
  80. Connect the following:
    • Coolant hose to the thermostat.
    • Coolant hose to the PCV fitting on the intake manifold.
      Fig 72: Connecting Coolant Hose To Thermostat & PCV Fitting On Intake Manifold
      G03273903Courtesy of FORD MOTOR CO.
  81. Install the right motor mount.
    Fig 73: Installing Right Motor Mount
    G03273904Courtesy of FORD MOTOR CO.
  82. Position the FEAD bracket and install the bolts in the sequence shown in two stages.
    • Stage 1: Install the bolts finger tight.
    • Stage 2: Tighten the bolts to 47 N.m (35 lb-ft).
      Fig 74: FEAD Bolts Tightening Sequence
      G03273905Courtesy of FORD MOTOR CO.
  83. Install the A/C compressor.
    Fig 75: Installing A/C Compressor
    G03273906Courtesy of FORD MOTOR CO.
    84. NOTE: Lubricate the O-ring seal with engine coolant.
    Fig 76: Installing Front Coolant Outlet Pipe
    G03273907Courtesy of FORD MOTOR CO.
  84. Install the front coolant outlet pipe.
    85. NOTE: Lubricate the O-ring seal with clean engine oil.
  85. Install the engine oil level indicator tube and the bolt.
    • Install the oil level indicator.
      Fig 77: Installing Oil Level Indicator
      G03273908Courtesy of FORD MOTOR CO.
  86. Install the accessory drive belt.
    Fig 78: Installing Accessory Drive Belt
    G03273909Courtesy of FORD MOTOR CO.
  87. Using the Spreader Bar and the Floor Crane, remove the engine from the Engine Stand.
  88. Install the flywheel or the flexplate and the bolts.
  89. Install the special tool.
    Fig 79: Installing Special Tool To Flywheel Or Flexplate
    G03273910Courtesy of FORD MOTOR CO.
  90. Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Tighten the bolts to 50 N.m (37 lb-ft).
    • Stage 2: Tighten the bolts to 80 N.m (59 lb-ft).
    • Stage 3: Tighten the bolts to 112 N.m (83 lb -ft).
      Fig 80: Flywheel Or Flexplate Bolts Tightening Sequence
      G03273911Courtesy of FORD MOTOR CO.

    91. VEHICLES WITH MANUAL TRANSMISSION 

  91. Lubricate the transmission input shaft pilot bearing with front axle grease.
    Fig 81: Lubricating Transmission Input Shaft Pilot Bearing
    G03273912Courtesy of FORD MOTOR CO.
  92. Adjust the clutch pressure plate.
    1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
    2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
    3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
      Fig 82: Adjusting Clutch Pressure Plate
      G03273913Courtesy of FORD MOTOR CO.
  93. Using the special tool, position the clutch disc on the flywheel.
    Fig 83: Using Special Tool To Position Clutch Disc On Flywheel
    G03273914Courtesy of FORD MOTOR CO.
    94. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
  94. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.
    • Remove the Clutch Disc Aligner.
      Fig 84: Removing Clutch Disc Aligner
      G03273915Courtesy of FORD MOTOR CO.
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