Part 2

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

Special Tools:

Special Tools:

Special Tools

Assembly (Continued)





35. Lay a new cylinder head gasket on the cylinder block.
1. Lay a new cylinder head gasket in place.
2. Screw in the guide studs made in the previous step.
3. Check that the alignment dowels are correctly seated.
36. Put the cylinder head in place.
^ Hook the cylinder head into the workshop hoist by the engine lifting eyes and move it into reposition.





37. CAUTION: Do not re-tighten the cylinder head bolts.

NOTE:
^ Screw in the cylinder head bolts free of oil.
^ Tighten the cylinder head bolts in three stages in the indicated sequence.

Attach the cylinder head.
^ Stage 1: 20 Nm
^ Stage 2: 40 Nm
^ Stage 3: 90 degrees
38. Lubricate the valve tappets with engine oil and fit them in the correct order.





39. NOTE: The identification numbers are located on the outside of the camshaft bearing caps.

Apply a thin coat of gasket maker to the marked areas on camshaft bearing caps 0 and 5.
40. Turn the crankshaft to approximately 60 degrees BTDC.





41. NOTE: Lay the camshafts in place with none of the cams at full lift.

Coat the camshafts and camshaft bearing caps with engine oil and insert them.





42. NOTE: Working in several stages, evenly screw in the camshaft bearing cap bolts in the indicated sequence, half a turn at a time, and then tighten them down in two stages.

Tighten the camshaft bearing caps.
^ Stage 1: 10 Nm
^ Stage 2: 19 Nm





43. Install the camshaft oil seals.
^ Lubricate the camshaft and the seal lip of the oil seal with engine oil.
^ Draw in the new oil seals using the special tool, a washer and an M10 x 70 bolt.





44. Turn the crankshaft to TDC on cylinder number 1.





45. NOTE: Cylinders 1 and 4 are at TDC when the Woodruff key points towards the piston.

Remove the blanking plug and align the crankshaft at TDC using the special tool.





46. Turn the camshafts to ignition point on cylinder number 1 and insert the special tool into the camshafts.

47. NOTE: Do not tighten the bolts. It must be possible to turn the timing pulleys on the camshafts. Slide the timing pulleys onto the camshafts and screw in the bolts.





48. Install a new gasket into the water pump.
1. Lay the gasket in place.
2. Secure the gasket by bending over the tabs.





49. CAUTION:
^ Do not kink the timing belt (do not bend the timing belt less than diameter of 35mm).
^ Do not rotate the crankshaft; as necessary check that it is still resting against the timing pin.

NOTE: The lug of the timing belt tensioner must not be hooked into the sheet metal cover during timing belt installation. Position a new timing belt in place.

1. Slide the crankshaft timing pulley with a thrust washer onto the crankshaft.
2. Attach the water pump.
3. Attach the upper idler pulley.
4. Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
5. Attach the timing belt tensioner and screw in the bolt five turns.





50. CAUTION: Incorrect timing belt tension will cause incorrect valve timing.

Pre tension the timing belt.
1. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
2. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position.
3. Tighten the attaching bold enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6mm ex key.





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

Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).





52. While holding the adjusting washer in position, tighten the bolt.





53. CAUTION: Do not tighten against Special Tool 303-465.

NOTE: Use the special tool to hold the timing pulleys.

Tighten the bolts on the timing pulleys.
54. Unscrew and remove Special Tool 303-574.
55. Take Special Tool 303-465 off the camshafts.

56. NOTE: Turn the engine two turns in the normal direction of rotation by the crankshaft.

Check the valve timing by inserting the special tools and correct the alignment as necessary.
^ Screw in Special Tool 303-574 and make sure that the crankshaft is resting against the special tool.
^ Insert Special Tool 303-465 into the camshafts. If necessary loosen the timing pulleys and correct the camshaft alignment.
^ Detach the special tools.





57. Install the blanking plug.





58. CAUTION:
^ Use a blunt object (a plastic cable tie) to apply the silicone grease to avoid damaging the spark plug connectors.
^ Push on the spark plug connectors, keeping then in line with the spark plugs.

NOTE: Coat the inside of the spark plug connector to a depth of 5-10 mm with silicone grease.

Install the cylinder head cover and the spark plugs.
1. Screw in the spark plugs.
2. Tighten the cylinder head cover bolts in two stages.
^ Stage 1: 2 Nm
^ Stage 2: 7 Nm
^ Push on the spark plug connectors until they click in place.





59. NOTE: Check the seating of the gasket on the upper timing belt cover and correct as necessary.

Attach the timing belt covers and the belt pulleys.
1. Lower timing belt cover
2. Crankshaft pulley/vibration damper
3. Upper timing belt cover
4. Center timing belt cover/front engine mounting bracket
5. Drive belt idler pulley
6. Water pump belt pulley





60. Connect the positive crankcase ventilation using a new seal.
1. Three bolts
2. One bolt





61. Attach the ancillary components on the exhaust side.
1. Bracket for air conditioning compressor.
2. Bracket for power steering pump to cylinder head.
3. Bracket for power steering pump to cylinder block.
62. Hook the engine by the engine lifting eyes onto the workshop hoist and detach it from the assembly stand.
^ Put the engine down onto the assembly stand and leave it hooked onto the workshop hoist.





63. NOTE: Coat the oil filter seal with engine oil.

Attach the ancillary components on the intake side.
1. Oil pressure switch
2. KS
3. Attach a new oil filter.
4. Generator bracket to cylinder block
5. Generator bracket to cylinder head





64. Attach the intake manifold.
^ Screw in five bolts and fit two nuts.





65. Attach the exhaust manifold to the cylinder head using the alignment spacers with the two outside bolts and a new manifold gasket.





66. CAUTION:
^ Do not allow debris to fall into the exhaust manifold.
^ Always follow the correct installation sequence for the catalytic converter in order to prevent damage.
^ Examine the seats and threads in the exhaust catalyst cone and EGR valve. Clean as required.

Loosen the bracket for the catalytic converter so that it can move freely.





67. NOTE:
^ Use a new gasket.
^ Do not fully tighten the nuts/bolts at this stage.

Position the catalytic converter on the exhaust manifold using new hardware.
68. Raise and support the vehicle.





69. Using a nut and bolt, temporarily secure the catalytic converter to the bracket at the rear.





70. Tighten the catalytic converter to the exhaust manifold.





71. NOTE:
^ Always use a new catalyst to EGR valve pipe assembly.
^ Loosely assemble the pipe to both the EGR valve and the exhaust catalyst before tightening the unions.

Attach the catalytic converter.
1. Tighten the bolts on the catalytic converter bracket.
2. Install a new EGR-pipe.
3. Attach the heat shield.





72. Attach the bracket for the catalytic converter.
^ Tighten the bolts.
^ Remove the temporary bolt from the rear catalytic converter bracket.





73. Attach the generator.
1. Screw in and tighten the bolt.
2. Tighten the bolt.
3. Connect the positive cable.





74. Connect the multiplug to the oil pressure switch and the KS.