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.


Special Service Tools:





Timing Tool, Camshaft Alignment T94P-6256-CH





Timing Peg, Crankshaft Position T97P-6000-A





Cam Sprocket Holding/Removing Tool T74P-6256-B

CAUTION: The maximum amount by which the engine management system will adjust the camshaft timing (VCT control unit) is limited to two degrees.
As a result of this an extremely high degree of accuracy is required for any work which affects the valve timing.

Note: The locations of engine mountings and engine support insulators are described looking from the transaxle to the engine.

Note: Operation steps which only apply to certain model variants and therefore do not apply to all vehicles are clearly marked with the statement (if necessary).


Installation





1. Rotate the crankshaft to TDC on cylinder No.1.





2. Unscrew the blanking plug.
- (if necessary) Insert the special tool.





3. Position cylinder No.4 to "valves overlap" and install the special tool.
1. Hold the camshafts by the hexagon using an open-end wrench and turn them in the direction of engine rotation.
2. Slide the special tool onto the ends of both camshafts.

4. CAUTION: Do not rotate the crankshaft; as necessary check that it is still resting against the timing pin.





Note: design WITH lower idler pulley shown (built up to 06/1999).





Note: design WITHOUT 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.
- (if necessary) Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.





5. 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 counterclockwise until the pointer and the mark are lined up. Torque to 25 Nm (18.5 ft/lbs).





6. 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 bolt. Torque to 68 Nm (50 ft/lbs).

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

Tighten the exhaust camshaft timing belt pulley bolt. Torque to 60 Nm (44.5 ft/lbs).





7. Remove the special tool.
- (if necessary) Install the blanking plug.
8. Unscrew the special tool T97-6000-A.





9. Remove the special tool.





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

Tighten the exhaust camshaft to stage 2. Torque to 120 Nm (89 ft/lbs).

11. Note: As necessary, only turn the engine in the 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 T94P-6256-CH does not fit into both camshaft slots, loosen the tensioner, the intake and exhaust camshaft pulley bolts and tension the timing belt.





12. Note: Use a new blanking plug.

Install in the blanking plug on the exhaust camshaft pulley. Torque to 37 Nm (27.5 ft/lbs).





13. Install the valve cover and spark plugs.
1. Install the spark plugs. Torque to 15 Nm (11 ft/lbs).
2. Install the valve cover. Torque to 7 Nm (62 in/lbs).





14. Install HT wires and crankcase ventilation hose.
1. Connect the crankcase ventilation hose.
2. Connect the HT wires to the spark plugs.





15. Install the appearance cover.
1. Install the bolts. Torque to 7 Nm (62 in/lbs).
2. Connect the solenoid valve electrical connector and press in the rubber seal.
16. Clip the throttle cable and the speed control cable to the appearance cover.





17. Note: Set the upper part of the engine front cover together with the center part in place.

Install the center part of the engine front cover/front engine mounting bracket. Torque to 50 Nm (37 ft/lbs).





18. Note: Check the seating of the upper part of the engine front cover gasket and correct as necessary.

1. Install the upper part of the engine front cover. Torque to 10 Nm (88 in/lbs).





19. Install the power steering pipe bracket to the engine lift eye.





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

Install the front engine mounting. Torque to 83 Nm (61 ft/lbs)

21. Remove the Floor jack.





22. Install the coolant expansion tank.
- (if necessary) Attach the speed control cable to the coolant expansion tank.
23. Raise and support the vehicle.





Vehicles with automatic transaxle

24. Note: Verify that the center bolt is centered in the support insulator.

Tighten the center bolt of the right-hand engine support insulator. Torque to 120 Nm (89 ft/lbs).





Vehicles with manual transaxle:
25. Note: Verify that the center bolt is centered in the support insulator.

Tighten the center bolt of the right-hand engine support insulator. Torque to 48 Nm (35.5 ft/lbs).





All Vehicles
26. Note: Verify that the center bolt is centered in the support insulator.

Tighten the center bolt of the left-hand engine support insulator. Torque to 120 Nm (89 ft/lbs).





27. Install the lower part of the engine front cover. Torque to 7 Nm (62 in/lbs).





28. Note: Using access hole in the bottom of transaxle case to stop rotation of engine.

Install the crankshaft pulley/vibration damper. Torque to 115 Nm (85 ft/lbs).





29. Note: Drive belt direction mark if belt is to be reused.

Install the accessory drive belt.
1. Install the belt idler pulley.
2 (if necessary) Install the water pump pulley.
3. Tension the belt tensioner clockwise and position the accessory drive belt in place.
4. Tighten the 3 water pump pulley bolts. Torque to 10 Nm (88 in/lbs).





30. Install the right-hand front lower splash shield.
31. Install the right-hand front wheel.
32. Lower the vehicle.





33. Tighten the right-hand front wheel. Torque to 128 Nm (95 ft/lbs).

34. 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.
35. Check the fluid levels and correct as necessary.
36. Check the routing of the vacuum hoses and wiring and secure them with cable ties.