[GK>\, 

& *

@ &  >

'&;
   !         
       <=<=  !=
.  =  !+">?  
"     =   
@J+  M .        
     .    =    !  
= !  .  = 

      !     

.  =  ! +">?  
<    . QUQ<JUX+">?YZQ\\^Q
<    . QUQ<_^_`X+">?YZQ\\^^
<    . QUQ<^`J+">?YZQ\\^J
<    . QUQ<^UZ+">?YZQ\\^`
<    . QQU<UZ`+">?YZQ\\^X

/ @ &  >J[GK>\K*K

 Group 00(L-Ford), Engine

I. ENGINE CONTROL MODULE II. ENGINE WIRE HARNESS

REPLACEMENT
1. Disconnect Negative battery cable.
2. Lay out the new wire harness, noting the location,
type of connectors, and identifying markings. Take
special note of identical or similar connectors (such
as the ignition coils or HEGO Sensors) to avoid
crossing connections during installation. Note the
routing of the existing wire harness in and around the
This procedure relates to removal and installation of the engine and the vehicle. Refer the Electrical Sche-
ECM--see Diagnostic Scan Tool for accessing ECM soft- matic.
ware. (Refer to the section 6.)
! CAUTION
REMOVAL PROCEDURE Ensure that all connections are made to the cor-
rect locations on the engine and its components.
1. Disconnect Negative battery cable.
Crossing connections may cause poor engine
2. Remove four screws mounting the controller to the performance, a MIL warning and/or perma-
mounting bracket. nent damage to the ECM.
3. Push connector lock back to unlock connector.
3. Remove all wire harness connectors on the vehicle.
4. Remove ECM.
4. Remove all clips and brackets holding the wire har-
ness and remove harness from vehicle.
INSTALLATION PROCEDURE 5. Lay the new wire harness over the engine and route
each end to its connection. Verify that all connectors
IMPORTANT match prior to installation.
The ECM is calibrated for each engine. Verify
6. Connect all connectors and ring terminals.
you have the correct controller by noting the
part number on the ECM label. The calibration 7. Install all clips and brackets to hold down the har-
number can also be found by connecting the ness.
Spectrum Engine Monitor and locating the cali- 8. Reconnect Negative battery cable
bration number on the Gauge page.
9. Start engine and verify engine is in closed loop and
1. Mount the ECM with four screws. no MIL light is present.
Torque to 10 Nm (7.4 lbf½ft.)
2. Plug connector into controller.
3. Push lock into place.
4. Reconnect the Negative battery cable.
5. Install Spectrum Engine Monitor.
6. Reconnect Negative battery cable
7. Start engine and verify engine is in closed loop and
no MIL light is present.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-2

 Group 00(L-Ford), Engine

III. IGNITION COIL IV. FUEL RAIL PRESSURE/ TEM-

PERATURE(FRT/FAP) SENSOR

Coil on Plug Ignition Coil

REMOVAL PROCEDURE
1. Disconnect Negative battery cable.
2. Remove electrical connector. Fuel Rail Sensor
3. Remove bolt securing the ignition coil.
4. Gently remove the ignition coil by pulling while
REMOVAL PROCEDURE
lightly twisting back and forth. 1. Disconnect the Negative battery cable.
2. Relieve the LPG fuel system pressure.
Refer to XX. LPG Fuel System Pressure Relief.
INSTALLATION PROCEDURE 3. Locate the Fuel Temperature Sensor on the center of
1. Insert Ignition coil into the opening on the cylinder the Fuel Rail and remove the electrical connector
head, ensuring the boot is properly placed on top of from the Sensor.
the spark plug and verify the coil is flush with top of 4. Using a 24mm wrench or deep socket, remove the
the cylinder head. Sensor from the Fuel Rail.
2. Secure Ignition Coil with bolt.
Torque to 10 Nm (7.4 lbf½ft).
! WARNING
Residual vapor pressure will be present in the
3. Reconnect electrical connector to the coil.
fuel system. Ensure the work area is well venti-
4. Reconnect Negative battery cable. lated before disconnecting any fuel line.
5. Start engine and verify engine is in closed loop and
no MIL light is present. INSTALLATION PROCEDURE
1. Lubricate O-rings on the sensor with petroleum jelly
or Vaseline.
2. Install the sensor into the fuel rail using 24mm socket
or wrench.
Torque to 20 +/-2 Nm (14.75 +/- 1.5 ft.lbs.).
3. Attach the electrical connector.
4. Reconnect the Negative battery cable.
5. Using the Spectrum Engine Monitor, clear DTC
information from the ECM.
6. Turn the ignition OFF and wait 30 seconds.
Check for leaks.
7. Reconnect Negative battery cable
8. Start engine and verify engine is in closed loop and
no MIL light is present.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-3

 Group 00(L-Ford), Engine

V. THROTTLE BODY AND/OR VI. REGULATOR

GASKET

Regulator

REMOVAL PROCEDURE REMOVAL PROCEDURE

1. Disconnect the Negative battery cable. 1. Relieve the LPG fuel system pressure. Refer to XX.
2. Remove the air intake. LPG FUEL SYSTEM PRESSURE RELIEF.

3. Remove Throttle Body electrical connector. 2. Disconnect Negative battery cable.

4. Remove four Bolts that secure the Throttle Body. 3. Remove the electrical connector on the Shutoff
Valve.
5. Remove the Throttle Body and the Gasket.
4. Remove the Fuel Hose from the regulator.
5. Remove the LPG Fuel Line at the flare fitting
INSTALLATION PROCEDURE attached to the Shutoff Valve.
1. Inspect Throttle Body Gasket. Replace if necessary.
2. Place Throttle Body and Gasket on the Intake Mani- ! CAUTION
fold plenum, align and secure with four Screws.
A small amount of fuel may still be present in
Torque to 10 Nm (7.4 ft. lbs.).
the fuel line. Use gloves and proper eye protec-
3. Connect electrical connector. tion to prevent burns. If liquid fuel continues to
4. Reconnect Negative battery cable. flow from the connections when removed, make
sure the manual valve is fully closed.
5. Start Engine. Verify correct operation in all throttle
ranges. 6. Clamp both Coolant Hoses as close to the Regulator
6. Using the Spectrum Engine Monitor, clear DTC as possible.
information from the ECM. 7. Remove Coolant Hoses from Regulator.
7. Reconnect Negative battery cable
8. Start engine and verify engine is in closed loop and ! CAUTION
no MIL light is present. The coolant may be hot. Use caution when
removing hose(s) to prevent contact.

8. Remove the Bolts securing the Regulator and remove

Regulator.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-4

 Group 00(L-Ford), Engine

INSTALLATION PROCEDURE IMPORTANT

1. Secure Regulator with Bolts. Draining the Regulator when the engine is
warm will help the oils to flow freely and permit
2. Attach the LPG Fuel Line at the flare fitting attached easier removal from the Regulator.
to the Shutoff Valve.
3. Reconnect LPG Fuel Line to Fuel Rail. To drain the Regulator, follow the steps below:
4. Connect Coolant Lines. Remove clamps from Hoses 1. Move the equipment to a well ventilated area and
(if used during removal). ensure no external ignition sources are present.
5. Slowly open LPG Tank Valve. 2. Turn off LPG Valve and Relieve the LPG fuel sys-
tem pressure. Refer to XX. LPG FUEL SYSTEM
IMPORTANT PRESSURE RELIEF.
The fuel cylinder manual valve contains an 3. Disconnect Negative battery cable.
Excess Flow Check Valve. Open the manual
valve slowly to prevent activating the Excess
Flow Check Valve. ! CAUTION
6. Reconnect Negative battery cable. Turn ignition key A small amount of fuel may still be present in
to ON and check for leaks at the inlet and outlet fit- the fuel line. Use gloves and proper eye protec-
tings using a commercial grade soapy solution or an tion to prevent burns. If liquid fuel continues to
electronic leak detector. If leaks are detected make flow from the connections when removed, make
repairs. sure the manual valve is fully closed.
7. Start engine and check for fuel and coolant leaks. 4. Remove the plug on the Regulator under the lower
If leaks are detected make repairs. coolant port.
8. Reconnect Negative battery cable 5. Place a small receptacle in the engine compartment
9. Start engine and verify engine is in closed loop and to catch any liquid that may come out of the Regulator.
no MIL light is present. 6. Inspect the Regulator for any large dried particles and
10. Check coolant level and add coolant if necessary. remove. Use a safety solvent to remove any build up.

IMPORTANT
Use only Safety Solvents for the cleaning of the
VII. CHECKING/DRAINING OIL regulator and its components. Solvents such as
carburetor or brake cleaners may damage gas-
BUILD-UP IN THE LOW
kets, seals, O-rings, diaphragms or other non-
PRESSURE REGULATOR metal components.
During the course of normal operation oil or “heavy ends” 7. Reinstall the Plug. Torque until tight.
may build inside the secondary chamber of the Regulator.
8. Connect Negative battery cable.
These oil and heavy ends may be a result of poor fuel
quality, contamination of the fuel, or regional variation of 9. Open Valve on LPG tank.
the fuel make up. A significant build up of oil can affect
IMPORTANT
the performance of the secondary diaphragm response.
The LPG CERTIFIED ENGINE MAINTENANCE The fuel cylinder manual valve contains an
REQUIREMENTS found in this manual recommends that Excess Flow Check Valve open the manual
the oil be drained periodically. This is the minimum valve slowly to prevent activating the Excess
requirement to maintain the emission warranty. More fre- Flow Check Valve.
quent draining of the Regulator is recommended for spe- 10. Turn Key ON. Check for leaks at the inlet and outlet
cial situation where substandard fuel may be a problem. fittings using a soapy solution or an electronic leak
IMPCO recommends the Regulator be drained at every detector. If leaks are detected make repairs.
engine oil change (500 hours) if contaminated or substan-
11. Start engine and check for leaks at all serviced fit-
dard fuel is suspected or known to be have been used or in
tings. If leaks are detected make repairs.
use with the emission complaint fuel system. This is
known as special maintenance, and failure to follow this 12. Dispose of any drained material in safe and proper
recommendation may be used to deny a warranty claim. manner.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-5

 Group 00(L-Ford), Engine

VIII. FUEL FILTER ELEMENTS 6. Connect the Negative battery cable.

7. Slowly open the fuel valve on tank.
REMOVAL PROCEDURE
IMPORTANT
1. Relieve the LPG fuel system pressure. Refer to XX.
The fuel cylinder manual valve contains an
LPG FUEL SYSTEM PRESSURE RELIEF.
Excess Flow Check Valve. Open the manual
2. Disconnect Negative battery cable. valve slowly to prevent activating the Excess
Flow Check Valve.
! CAUTION 8. Turn the key to the ON position and back to the OFF
A small amount of fuel may still be present in position to pressurize the fuel system.
the fuel line. Use gloves and proper eye protec- Check for leaks.
tion to prevent burns. Make sure the manual 9. Check for leaks at connections by using soapy solu-
valve is fully closed. tion or electron leak detector. If leaks are detected,
make proper repairs.
10. Start engine and ensure correct operation in all throt-
tle ranges.
11. Check for leaks at connections by using soapy solu-
tion or electron leak detector. If leaks are detected,
make proper repairs.

IX. LOCK-OFF SOLENOID

1. Relieve the LPG fuel system pressure. Refer to XX.
LPG FUEL SYSTEM PRESSURE RELIEF.
2. Disconnect Negative battery cable.
Regulator, showing filter related components. 3. Disconnect the electrical connector from the lock-off
solenoid.
3. Disconnect the fuel inlet and outlet lines from the
LPG Regulator. 4. Remove the nut and solenoid.
4. Remove the fuel inlet fitting (11) and O-ring (10).
5. Remove the plastic body (9), foam filter (8), paper INSTALLATION PROCEDURE
filter element (7), and filter gasket (6). 1. Install new cartridge into LPG Regulator. Tighten
6. Remove the screws (5), fuel outlet fitting (4) Oring cartridge to 16 to 24 Nm (11.8 to 17.7 ft.lbs.).
(3), and filter (2). Discard O-ring and filter. 2. Install solenoid and nut onto cartridge.
Tighten nut to 7.85 Nm (69.5 in.lbs.).
INSTALLATION PROCEDURE 3. Connect electrical connector to solenoid.
1. Install new filter (2) in port for fuel outlet fitting. 4. Connect the Negative battery cable.
Install new O-ring (3) and fuel outlet fitting (4).
IMPORTANT
2. Install retaining screws (5) for fuel outlet fitting (4).
The fuel cylinder manual valve contains an
Tighten screws to 2 to 3 Nm (17.7 to 26.55 in.lb.).
Excess Flow Check Valve. Open the manual
3. Install the filter gasket (6), new paper filter element valve slowly to prevent activating the Excess
(7), new foam filter (8), and plastic body (9). Flow Check Valve.
4. Install the fuel inlet fitting (11) and O-ring (10).
Tighten to 18 to 20 Nm (13.3 to 14.75 ft.lbs.). 5. Slowly open the fuel valve on tank.
5. Connect the fuel inlet line to the LPG Regulator.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-6

 Group 00(L-Ford), Engine

6. Turn the key to the ON position and back to the OFF INSTALLATION PROCEDURE
position to pressurize the fuel system.
1. Install Fuel Pressure Sensor, if removed Refer to IV
Check for leaks.
FUEL RAIL PRESSURE/ TEMPERATURE (FRT/
7. Check for leaks at connections by using soapy solu- FAP) SENSOR REPLACEMENT
tion or electron leak detector. If leaks are detected,
2. Lubricate Fuel Injector O-rings with petroleum jelly
make proper repairs.
or Vaseline.
8. Start engine and ensure correct operation in all throt-
3. Carefully place the Injector Ports into the Fuel Rail.
tle ranges.
Ensure the Fuel Injectors and O-rings are properly
9. Check for leaks at connections by using soapy solu- seated.
tion or electron leak detector. If leaks are detected,
4. Align holes on Fuel Rail with holes in the bracket
make proper repairs.
and ignition noise suppressor and insert screws.
Torque to 10 Nm (7.4 ft. lbs.).
5. Connect Fuel Pressure Sensor electrical connection.
X. FUEL RAIL
6. Insert fuel inlet port fitting and secure with pin.
7. Reconnect Negative battery cable. Turn ignition key
to ON and check for leaks at the inlet and outlet fit-
tings using a commercial grade soapy solution or an
electronic leak detector. If leaks are detected make
repairs.
8. Reconnect Negative battery cable.
9. Start engine and check leaks. If leaks are detected
Fuel Rail with Injectors and FRT/FRP Sensor make repairs.
10. Verify engine is in closed loop and no MIL light is
REMOVAL PROCEDURE present.
1. Relieve the LPG fuel system pressure. Refer to XX.
LPG FUEL SYSTEM PRESSURE RELIEF.
2. Disconnect the Negative battery cable.
3. Remove the pin securing the fuel inlet hose, then
remove fitting from the fuel rail.

! CAUTION
A small amount of fuel may still be present in
the fuel line. Use gloves and proper eye protec-
tion to prevent burns. If liquid fuel continues to
flow from the connections when removed, make
sure the manual valve is fully closed.

4. Remove Fuel Pressure Sensor electrical connection.

5. Remove two bolts securing the Fuel Rail, including
the ignition noise suppressor.
6. Carefully pull the rail flush along the Fuel Rail and
away from the Fuel Injectors.
7. If rail is to be replaced, remove the Fuel Pressure
Sensor. Refer to IV FUEL RAIL PRESSURE/TEM-
PERATURE (FRT/FAP) SENSOR.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-7

 Group 00(L-Ford), Engine

XI. FUEL INJECTOR 5. Install Fuel Rail. Refer to IX. FUEL RAIL
6. Connect the electrical connector(s) to the fuel injec-
tor(s). Verify that the connectors click/lock into
place.
7. Connect the Fuel Line Port Fitting to the Fuel Rail
and secure with Retaining Pin.
8. Reconnect Negative battery cable. Turn ignition key
to ON and check for leaks at the inlet and outlet fit-
tings using a commercial grade soapy solution or an
electronic leak detector. If leaks are detected make
repairs.
9. Reconnect Negative battery cable.
10. Start engine and check leaks. If leaks are detected
make repairs.
Fuel Injector
11. Verify engine is in closed loop and no MIL light is
present.
REMOVAL PROCEDURE
1. Relieve the LPG fuel system pressure. Refer to XX.
LPG FUEL SYSTEM PRESSURE RELIEF. XII. FUEL INJECTOR ADAPTERS
2. Disconnect the Negative battery cable.
REMOVAL PROCEDURE
3. Remove the Fuel Rail. Refer to X. FUEL RAIL.
4. Remove Injector electrical connector.
5. Remove Clip Retaining Fuel Injector (connecting it
to the Injector Adapter).

! CAUTION
When removing the fuel injectors, pull the Fuel Injector Adapter (shown without O-rings)
injectors straight out. Do not pry the injectors
with a screwdriver or prybar, as this can dam- 1. Relieve the LPG fuel system pressure. Refer to XX.
age the injectors or injector adapters. LPG FUEL SYSTEM PRESSURE RELIEF.
2. Disconnect the Negative battery cable.
6. Remove Injector.
3. Remove the Fuel Rail. Refer to X. FUEL RAIL.
4. Remove the Injector(s).
INSTALLATION PROCEDURE Refer to XI. FUEL INJECTOR.
1. Inspect the O-rings on the Injector and Injector 5. Remove the Fuel Injector Adaptor(s) from the Intake
Adapter and replace if necessary. Lubricate with Manifold using an 8mm hex wrench.
Vaseline or petroleum jelly.
6. Place tape or rag over the opening in the Intake Man-
2. Install the Fuel Injectors into the Fuel Injector Adapt- ifold to prevent dirt or debris from entering the
ers. Push the Injectors into the Adapters using hand engine, possibly causing permanent engine damage.
pressure only.
3. Install the Clip Retaining Fuel Injector (connecting it
to the Injector Adapter).
4. Ensure all Injectors are properly aligned to mate to
the Fuel Rail.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-8

 Group 00(L-Ford), Engine

INSTALLATION PROCEDURE XIII. TEMP/MANIFOLD PRESSURE

1. Lubricate the O-rings on the Fuel Injector Adapter (TMAP) SENSOR
with Vaseline or petroleum jelly and place back on
the Intake Manifold, ensuring it is properly seated.
Using a 8mm hex wrench, torque to 5Nm (3.7
ft.lbs.).

! WARNING
Contamination of the HEGO sensor can result
from the use of an inappropriate RTV sealer or
silicone spray products. Do not use silicone
sprays or hoses which are assembled using sili-
cone lubricants. Always use “oxygen sensor TMAP Sensor
safe” RTV sealant for repair procedures.
Silicon contamination will cause a high but false
HEGO signal voltage (rich exhaust indication). REMOVAL PROCEDURE
The ECM will then reduce the amount of fuel
delivery to the engine, causing a severe drive- 1. Disconnect the Negative battery cable.
ability problem. If silicone contamination is sus- 2. Locate the TMAP Sensor on the outside of the Intake
pected, remove and visually inspect the sensor Manifold.
element. If contaminated, the portion of the sen-
3. Remove electrical connector.
sor exposed to the exhaust stream will have a
white powdery coating. Always be sure to elimi- 4. Remove the bolt securing the TMAP, then pull from
nate the cause of contamination before replac- the intake manifold.
ing the sensor.

2. Install Injectors on top of Adapters. INSTALLATION PROCEDURE

Refer to XI. FUEL INJECTOR. 1. Install the TMAP and torque the bolt to Torque to
3. Install Fuel Rail. Refer to X. FUEL RAIL. 10 Nm (7.4 ft. lbs.).
4. Reconnect Negative battery cable. Turn ignition key 2. Connect electrical connector.
to ON and check for leaks at the inlet and outlet fit- 3. Reconnect the Negative battery cable.
tings using a commercial grade soapy solution or an
electronic leak detector. If leaks are detected make 4. Start engine and verify engine is in closed loop and
repairs. no MIL light is present.

5. Start engine and check leaks. If leaks are detected

make repairs.
6. Verify engine is in closed loop and no MIL light is
present.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-9

 Group 00(L-Ford), Engine

XIV. INTAKE MANIFOLD/GASKET

REMOVAL PROCEDURE
1. Relieve the Fuel Pressure refer to XX. LPG FUEL
PRESSURE RELIEF. Intake Manifold footprint showing bolt tightening
2. Disconnect Negative battery cable. sequence.
3. Disconnect electrical connectors to the Throttle Body 5. Connect black PCV hose to the larger hose barb.
and TMAP Sensor. If the Intake Manifold is to be 6. Connect the orange hose to the smaller hose barb.
replaced, remove the Throttle Body and TMAP sen-
sor. Refer to V Throttle Body and XIII TMAP Sen- 7. Install Fuel Injectors (if removed).
sor. Refer to XI. FUEL INJECTORS.

4. Remove Retaining Clip and Fuel Rail Port Fitting. 8. Install (if removed) FUEL RAIL.
Remove Fuel Rail. Refer to X. Fuel Rail. Refer to FUEL RAIL PRESSURE/TEMPERATURE
(FRT/FAP) SENSOR.

! 9. If TMAP Sensor was removed, install.

WARNING
Refer to XIII. TMAP Sensor.
Residual vapor pressure will be present in the
fuel system. Ensure the work area is well venti- 10. If the Throttle Body was removed, install.
lated before disconnecting any fuel line. Refer to V Throttle Body.
11. Reconnect Negative battery cable. Turn ignition key
5. Remove two bolts securing the fuel rail. to ON and check for leaks at the inlet and outlet fit-
6. Remove black PCV hose from hose barb on the tings using a commercial grade soapy solution or an
Intake Manifold. electronic leak detector. If leaks are detected make
repairs.
7. Remove orange hose from hose barb (note that it
may be covered with black conduit). 12. Using the Spectrum Engine Monitor, clear DTC
information from the ECM.
8. Remove five Bolts securing Intake Manifold and
remove. 13. Start engine and verify engine is in closed loop and
no MIL light is present.
9. Remove Intake Manifold Gasket.

INSTALLATION PROCEDURE
1. Ensure the mating surfaces of the intake ports on the
engine and manifold are clean and free of any gasket
material.
2. If installing a new Intake Manifold, apply Loctite
567 and thread hose barbs (small for the TMAP and
larger for PCV).
Torque both to 2-3 turns past finger tight.
3. Insert five mounting Bolts through holes in Intake
Manifold. Hang the Intake Manifold Gasket on the
bolts, position the Gasket and Intake Manifold in
place and finger tighten Bolts.
4. Torque Bolts to 20 NM (37 ft.lbs) in the following
order: middle, two upper, two outer/lower in the
order shown:

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-10

 Group 00(L-Ford), Engine

XV. ENGINE COOLANT TEMPERA- XVI. HEATED EXHAUST GAS

TURE SENSOR (ECT) OXYGEN SENSOR (HEGO)

Coolant Temperature Sensor The Heat Exhaust Gas Oxygen (HEGO) Sensor

NOTE
REMOVAL PROCEDURE There are two HEGO sensors: one between the
1. Disconnect the Negative battery cable. engine and catalytic converter (upstream) and
one between the catalytic converter and tail
2. Locate the Engine Coolant Temperature Sensor on pipe(downstream). The replacement and instal-
the top of the engine. lation procedure for both is the same.
3. Remove electrical connector.
4. Using an extra deep 24 socket or a Ford Special Ser- REMOVAL PROCEDURE
vice tool, remove the sensor.
1. Disconnect Negative battery cable.

! 2. Locate the affected Oxygen Sensor on the exhaust

CAUTION
pipe and disconnect the Oxygen sensor electrical
The coolant may be hot. Use caution when t pre- connector.
vent contact with coolant or related compo
nents. 3. Using an Oxygen Sensor socket or open end wrench,
remove the Oxygen Sensor.

INSTALLATION PROCEDURE
INSTALLATION PROCEDURE
1. Apply a minimal amount of pipe thread sealer to
threads on the Engine Coolant Temperature Sensor. IMPORTANT
Remove any excess sealer on threads or the sensor. Before install the Oxygen Sensor lubricate
2. Install Engine Coolant Temperature Sensor. threads with a high temperature anti-seize com-
Torque to 12 Nm (106 in.lbs.). pound. Avoid contaminating sensor tip with
compound.
3. Reconnect electrical connector.
4. Start engine and verify engine is in closed loop and 1. Install Oxygen Sensor.
no MIL light is present. Torque to 50 Nm (37 ft.lbs.).
2. Reconnect electrical connector to the Oxygen Sen-
sor.
3. Reconnect Negative battery cable.
4. Start engine and verify engine is in closed loop and
no MIL light is present.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-11

 Group 00(L-Ford), Engine

XVII. EXHAUST MANIFOLD 7. Connect Exhaust Piping.

8. Reconnect Negative battery cable.
9. Start engine and verify engine is in closed loop and
no MIL light is present.

XVIII. RESTRICTED EXHAUST

SYSTEM DIAGNOSIS

REMOVAL PROCEDURE
1. Disconnect Negative battery cable.
2. Remove four Bolts securing Exhaust Heat Shield
3. Remove HEGO Sensor. Refer to XVI. HEATED
EXHAUST GAS OXYGEN SENSOR(HEGO).
4. Remove two nuts securing exhaust piping to the
Exhaust Manifold and separate piping from the studs
on the Exhaust Manifold.
5. Remove seven Bolts securing Exhaust Manifold and
remove Exhaust Manifold and Gasket.

INSTALLATION PROCEDURE
1. Ensure the mating surface of the Cylinder Head is
clean and free from gasket debris. 1 Back Pressure Gauge
2 Heated Exhaust Gas Oxygen (HEGO) Sensor.
2. Insert seven Bolts into the Exhaust Manifold and
3 Exhaust Manifold
hang the Gasket on the Bolts.
3. Align Exhaust Manifold and thread Bolts into the Exhaust Back Pressure Test
Cylinder Head and finger tighten. Torque to 38 Nm
(28 ft.lbs) in the following sequence: PROCEDURE:
1. Carefully remove the HEGO.
Refer to XVI. HEATED EXHAUST GAS OXYGEN
SENSOR (HEGO).
2. Install Exhaust Back Pressure Test Gauge(J35314-A)
Exhaust Manifold footprint showing
in place of the HEGO.
Bolt tightening sequence.
3. With the engine idling at normal operating tempera-
4. If the Exhaust Manifold is being replaced, insert two
ture, observe the exhaust system back pressure read-
studs on the flange and torque to 15Nm (11 ft.lbs).
ing on the gauge. Reading should not exceed 8.6 kPa
5. Install HEGO Sensor. Refer to XVI HEGO Sensor. (1.25 psi).
6. Install Heat Shield with four Bolts. 4. Increase engine speed to 2000 RPM and observe
Torque to 10Nm (7.4 ft.lbs.). gauge. Reading should not exceed 20.7 kPa (3 psi).

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-12

 Group 00(L-Ford), Engine

5. If the back pressure at either speed exceeds specifica-

tion, a restricted exhaust system is indicated. ! WARNING
6. Inspect the entire exhaust system for a collapsed Residual vapor pressure will be present in the
pipe, heat distress or possible internal catalytic con- fuel system. Ensure the work area is well venti-
verter failure. Repair as necessary. lated before disconnecting any fuel line.

7. If there are no obvious reasons for the excessive back

pressure, the catalytic converter is likely damaged ! CAUTION
and should be replaced. Never use an open flame of any type to check
LPG leaks.

Always inspect the LPG fuel system for leaks after per-
XIX. CATALYTIC CONVERTER forming service. Check for leaks at the fittings of the ser-
viced or replaced component. Use a commercially
REMOVAL PROCEDURE available liquid leak detector or an electronic leak detec-
1. Disconnect negative battery cable. tor. When using both methods, use the electronic leak
detector first to avoid contamination by the liquid leak
2. Remove the Catalytic Converter using the OEM end
detector.
product processes.

INSTALLATION PROCEDURE XXI. LPG FUEL SYSTEM

IMPORTANT PRESSURE CHECK
The Catalytic converter is specifically designed 1. Turn ignition to OFF.
to meet the emission control of the certified
engine. Use only the OEM specified part. 2. Connect the Spectrum Monitor and view the fuel
Install the Catalytic Converter using the OEM pressure on the Gauge Page.
end product processes. 3. In the event the pressure reading and Fuel Rail Pres-
sure Sensor are suspect, the pressure can be manually
1. Reconnect Negative battery cable. read by removing the plug on the end of the rail
2. Start engine and verify engine is in closed loop and (opposite the fuel inlet port). Prior to removing the
no MIL light is present. plug, relieve the Fuel Pressure refer to XX. LPG
FUEL PRESSURE RELIEF. Next, remove the plug
on the end of the Fuel Rail and install a fitting, hose
and pressure gauge. Reconnect the Negative battery
XX. LPG FUEL PRESSURE RELIEF cable and turn the key to ON. Note the fuel pressure,
then start the engine and note the pressure when the
! CAUTION engine is running.
The LPG fuel system operates at pressure up to 4. Apply a minimal amount of pipe thread sealer, then
21.5 bar (312 psi). To minimize personal injury, replace Plug. Torque until tight.
relieve the LPG fuel system pressure before ser-
vicing the LPG fuel system components.

1. Close the manual shut-off valve (MSV) on the LPG XXII. LPG FUEL CONTROL
fuel tank. SYSTEM CHECK
2. Start and run the vehicle until the engine stalls from The fuel system can be thoroughly diagnosed by use of
lack of fuel. the Spectrum Engine Monitor tool. See section Spectrum
3. Turn the ignition switch to OFF. Engine Monitor.
4. Disconnect the Negative battery cable.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-13

 Group 00(L-Ford), Engine

XXIII. LPG FUEL SYSTEM REMOVAL PROCEDURE

LEAK TEST 1. Disconnect Negative battery cable.
There are two leak checks that can done on this fuel sys- 2. Remove the electrical connector.
tem: A commercially available liquid leak detector or an 3. Remove the bolt securing the Camshaft Sensor.
electronic leak detector can be used to detect leaks. Be
sure to follow the manufacturers’ instructions.
INSTALLATION PROCEDURE
IMPORTANT
1. Mount Camshaft Sensor.
When using both methods, use the electronic
Secure with Bolt and torque to 7 Nm (5.2 ft.lbs.).
leak detector first to avoid contamination by the
liquid leak detector. NOTE
1. The injectors can be tested for an internal leak Spacing is important for the sensor to properly
(excess fuel flow or leakage into the cylinders) and read the wheel. Make sure the sensor is prop-
all of the fuel passages downstream of the regulator erly positioned and seated.
can be tested as follows:
2. Replace valve cover.
• Key ON, engine OFF. Refer to XXXVIII. Valve Cover.
• Using the Spectrum Engine Monitor, plot the fuel 3. Connect electrical connect to the Camshaft Sensor.
pressure on the Plot page or note the pressure on
the Monitor page. 4. Reconnect Negative battery cable.
• Note the fuel pressure (as measured in the fuel rail 5. Start engine and verify engine is in closed loop and
by the FRT/FRT sensor) for 25 seconds. no MIL light is present.
• After an additional 25 seconds, note any drop in
fuel rail pressure. A drop of more than 3 kPa in 25
seconds is excessive and indicates a leaking injec-
tor(s), fuel hose, fitting, etc., downstream of the
XXV. CRANKSHAFT POSITION
regulator. Use a leak detector to determine if the SENSOR
fuel is leaking outside of the fuel system. If no leak
is found, an injector is leaking and should be
replaced. Refer to XI. Fuel Injector.

XXIV. CAMSHAFT POSITION

SENSOR

Crankshaft Position Sensor

REMOVAL PROCEDURE
1. Disconnect Negative battery cable.
2. Remove the electrical connector.
Camshaft Sensor
3. Remove the Bolts and the Crankshaft Sensor.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-14

 Group 00(L-Ford), Engine

INSTALLATION PROCEDURE XXVII. THERMOSTAT AND/OR

1. Mount Camshaft Sensor with Bolt and torque to HOUSING
7 Nm (5.2 ft.lbs.).

NOTE
Proper spacing is crucial to ensure the sensor
can accurately read the wheel. Verify that the
sensor is properly seated and the screws secur-
ing it are not cross threaded.

2. Connect electrical connector.

Coolant Housing & Hose.
3. Reconnect Negative battery cable.
4. Verify engine is in closed loop and no MIL light is REMOVAL PROCEDURE
present. 1. Disconnect Negative battery cable.
2. Drain coolant.
Refer to XL. DRAINING THE COOLANT.
XXVI. VACUUM LINE
REMOVAL PROCEDURE
! CAUTION
The coolant may be hot. Use caution when
1. Disconnect Negative battery cable. removing hose(s) to prevent contact.
2. Remove the Vacuum Line from each fitting.
3. Remove clamps from Hoses connecting to the Ther-
3. Inspect for rotting, deterioration, holes and tears and mostat Housing and remove Hoses.
replace if necessary.
4. Remove three Bolts securing Thermostat Housing
4. Reconnect to fittings using petroleum jelly or Vase-
line if necessary. 5. Remove Thermostat Housing and Thermostat.

INSTALLATION PROCEDURE INSTALLATION PROCEDURE

IMPORTANT IMPORTANT
DO NOT use a hose other than the OEM speci- Coolant hoses are specifically designed for their
fied part. application. DO NOT use hose material or
length other than the OEM specified parts. DO
1. Reinstall the Fuel Vapor Hose to each fitting. NOT mix the inlet or outlet ends of the Hose
when reinstalling.
2. Reconnect Negative battery cable.
3. Start engine and check for leaks using a soapy solu- 1. Ensure the mating surfaces are clean and free of any
tion or an electronic leak detector. If leaks are debris.
detected make repairs. 2. Insert Thermostat into Housing.
4. Verify engine is in closed loop and no MIL light is 3. Place Bolts into Housing and thread into engine.
present. Torque to 10 Nm (7.4 ft.lbs).
4. Connect Hoses to Housing and secure with clamps.

NOTE
If the hose is replaced, a section of it equal to the
length of the Y-adapter must be removed to
accommodate the Y-adapter.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-15

 Group 00(L-Ford), Engine

5. Refill with coolant. INSTALLATION PROCEDURE

6. Reconnect negative battery cable.
IMPORTANT
7. Start engine and let run until it reaches operating Coolant hoses are specifically designed for their
temperature. application. DO NOT use hose material or
8. Check for leaks. If leaks are detected, make repairs. length other than the OEM specified parts. DO
NOT mix the inlet or outlet ends of the Hose
9. Stop engine and allow to cool. Check coolant level
when reinstalling.
and add coolant as necessary.
1. Ensure the mating surfaces are clean and free of any
gasket material.
XXVIII. COOLANT PLATE & HOSES 2. Place Bolts into the Water Outlet Adapter Housing
and through the Gasket. Thread Bolts into engine and
torque to 10 Nm (7.4 ft.lbs).
3. Insert Bolts through Blanking Plate and Gasket(if
removed). Thread Bolts into engine and torque to 20
Nm (15 ft.lbs.).
4. If the Water Outlet Adapter is being replaced, the
Plug must be replaced
5. Thread the Plug into the Adapter.
Torque to 15 Nm (11 ft.lbs.).
6. Connect Hoses to Housing and secure with clamps.
7. Refill with coolant.
8. Reconnect Negative battery cable.
9. Start engine and let run until it reaches operating
temperature.
10. Verify engine is in closed loop and no MIL light is
present.
Coolant Plate, Gaskets, Bolts & Hoses
11. Check for leaks. If leaks are detected, make repairs.
REMOVAL PROCEDURE 12. Stop engine and allow to cool. Check coolant level
1. Disconnect Negative battery cable. and add coolant as necessary.
2. Drain coolant.
Refer to XL. DRAINING THE COOLANT

! CAUTION
The coolant may be hot. Use caution when
removing hose(s) to prevent contact.

3. Remove clamp from Hose and remove Hose con-

necting to the Water Outlet Adapter.
4. Remove for Bolts securing the Adapter, Blanking
Plate and Gaskets and remove all of these compo-
nents.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-16

 Group 00(L-Ford), Engine

XXIX. COOLANT TUBE & O-RINGS 6. Reconnect Negative battery cable.

7. Start engine and verify engine is in closed loop and
no MIL light is present.
8. Check for leaks. If leaks are detected, make repairs.
9. Stop engine and allow to cool. Check coolant level
and add coolant as necessary.

XXX. ALTERNATOR
REMOVAL PROCEDURE
Coolant Tube, O-rings and Bolts. 1. Disconnect Negative battery cable.
2. Disconnect wires to the alternator.
REMOVAL PROCEDURE
3. Remove top Bolt securing Alternator.
1. Disconnect Negative battery cable.
4. Loosen lower Bolts.
2. Drain coolant.
5. Remove Serpentine belt.
Refer to XL. DRAINING THE COOLANT
6. Remove two lower bolts securing the alternator.
! CAUTION
The coolant may be hot. Use caution when mov- INSTALLATION
ing hose(s) to prevent contact. 1. Place alternator so the side with two mounting ears
mate up with the two tabs of the lower Alternator
3. Remove clamps from Hose connecting to the Cool- Bracket.
ant Tube and remove Hose.
2. Insert Bolts through the two lower tabs and finger
4. Remove two Bolts securing the Tube. tighten.
5. Gently pulling forward, remove the end of the Tube 3. Place Serpentine Belt over the Alternator pulley,
from the Water Outlet Adapter. ensuring the belt is placed over the inner most
grooves.
INSTALLATION PROCEDURE 4. Rotate the Alternator outward until it the holes in the
upper tab and alternator bracket meet and install
IMPORTANT Bolt. Torque all three Bolts to 20 Nm (15 ft.lbs.).
Coolant hoses are specifically designed for their
5. Attach the wires to the Alternator.
application. DO NOT use hose material or
length other than the OEM specified parts. DO 6. Reconnect Negative battery cable.
NOT mix the inlet or outlet ends of the Hose 7. Start engine and verify engine is in closed loop and
when reinstalling. no MIL light is present.
1. Place O-rings over end of the Coolant Tube.
Lube with petroleum jelly or Vaseline.
2. While gently pushing towards the back of the engine,
insert the Tube into Water Outlet Adapter.
3. Insert Bolts through the plate on the Coolant Tube
and torque to 38 Nm (28 ft.lbs.).
4. Connect Hose to the Tube and secure with clamp.
5. Refill with coolant.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-17

 Group 00(L-Ford), Engine

XXXI. PULLEYS/BELT - HIGH 6. Remove the three Bolts securing the outer crankshaft
pulley. Refer to XXXII. CRANK-SHAFT PULLEY
MOUNT for instructions on how to remove the Crankshaft
pulley.
NOTE
This application has two serpentine belts.
This instruction set covers removal and replace- INSTALLATION PROCEDURE
ment of the outside belt and pulleys (except the
1. Install the Crankshaft Pulley if removed (Refer to
Crankshaft Pulley-refer to the next step) as
XXXII. CRANKSHAFT PULLEY.)
shown below:
2. Install three Bolts and Washers securing the outer
Crankshaft Pulley and Sleeve.
Torque Bolts to 17-20 ft.lbs (23-27 Nm).
3. If removed, install the Idler/Tensioner to the Fan
Bracket. Insert the two Bolts used to secure the Idler/
Tensioner through the mounting holes and into the
Bracket. Torque Bolts to 17-20 ft.lbs (23-27 Nm).
4. If removed, install the high mount Fan Pulley and
Fan with four Bolts.
Torque Bolts to 17-20 ft.lbs (23-27 Nm).
5. Install the three Bolts at the top of the Bracket and
secure the Bracket to the Engine.
Torque Bolts to 33-36 ft.lbs. (45-49 Nm).
6. If removed, install the small Pulley and Torque Bolts
to 17-20 ft.lbs (23-27 Nm).
7. Place the Serpentine Belt on all Pulleys, except the
Tensioner Pulley as shown in the drawing on the pre-
vious page. Using an open end or crescent wrench on
the boss behind the Idler Pulley, move the Tensioner
back and place the Serpentine over the Pulley, the
High mount fan six groove belt and
release the tension.
pulley assembly (Outside).
8. Reconnect Negative Battery Cable.
9. Start engine and verify engine is in closed loop and
REMOVAL PROCEDURE
no MIL light is present
1. Disconnect Negative battery cable.
2. Using an open end or crescent wrench on the boss
behind the Idler, release the tension on the Serpentine
Belt and remove from the Idler Pulley. Release the
tension on the Idler, then remove the Belt from the
other Pulleys. If service is not required to the Fan
Pulley, the Fan Hub Assembly can be removed with-
out disassembly of the Fan and Pulleys.
3. Optional: Remove the four Bolts securing the Fan
and Fan Pulley. Remove the Fan and Pulley from the
Fan Mount Hub.
4. Remove the three Bolts on top of the Fan Assembly
Bracket.
5. Optional: Remove small Pulley, then remove Idler.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-18

 Group 00(L-Ford), Engine

XXXII. CRANKSHAFT PULLEY crankshaft pulley must be held in place with the
Crankshaft Damper Holding Tool, and the bolt
REMOVAL PROCEDURE should be removed using an air impact wrench
(1/2-in drive minimum).

! WARNING 6. Install Ford Special Service Tool 303-1416 to secure

Do not install the crankshaft pulley bolt without the crank pulley: Using an M6 bolt, align the hole at
first installing the special tools as instructed in the bottom of the Crankshaft Pulley to the hole in the
this procedure. The crankshaft pulley and the cover. Insert bolt and finger tighten.
crankshaft timing sprocket are not keyed to the
crankshaft. The crankshaft, the crankshaft
sprocket and the pulley are fitted together by
friction, using diamond washers between the
flange faces on each part. For that reason, the
crankshaft sprocket is also unfastened if the
pulley bolt is loosened. Before any repair
requiring loosening or removal of the crank-
shaft pulley bolt, the crankshaft and camshafts
must be locked in place by the special service
tools, otherwise severe engine damage can Install Ford Special Service Tool 303-1416
occur.
7. Remove the crankshaft pulley bolt using an air
1. Disconnect Negative battery cable. impact wrench and remove pulley.
2. Remove the serpentine belt. NOTE
Refer to XXXI. PULLEYS/BELT—HIGH MOUNT. The crankshaft sprocket diamond washer may
3. Remove the three bolts securing the outer crank pul- come off with the crankshaft pulley.
ley to the inner crank pulley.
8. Keep all Ford Special tools in place until the Crankshaft
4. Remove the bolt in the side of the engine (as shown Pulley is installed to prevent engine from moving.
in the illustration) and insert Ford Special Service
Tool, 303-507.
INSTALLATION
NOTE
Failure to position the No. 1 piston at TDC can
result in damage to the engine. Avoid rotating
the engine. If the engine is turned, turn in the
normal direction of rotation (clockwise as
viewed from the front/fan side) only.

1. Insert Ford Special Service Tool 303-507.

Install Special Service Tool: 303-507.

5. Using a large breaker or Johnson bar, rotate the
engine in the normal direction until cylinder 1 is at
TDC (it will stop when it hits the Special Service
Tool, 303-507.

NOTE
The crankshaft must remain in the TDC posi-
tion during removal of the pulley bolt or dam-
age to the engine can occur. Therefore, the Install Special Service Tool: 303-507.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-19

 Group 00(L-Ford), Engine

NOTE
The Crankshaft TDC Timing Peg will contact
the crankshaft and prevent it from turning past
TDC. However, the crankshaft can still be
rotated in the counterclockwise direction. The
crankshaft must remain at the TDC position
during the crankshaft pulley removal and
installation.

NOTE
If the engine was not turned and Ford SST 303- Arrow depicting diamond washer.
1416 remained in place after the removal of the 5. If the Ford Special Service Tool was removed during
crank pulley, continue to Step 4. If replacing removal of the Crank Pulley, mount Ford SST 303-
camshafts, refer to XXXXI. CAMSHAFT AND/ 1416 using an M6 bolt, align the hole at the bottom
OR TAPPET REPLACEMENT, then continue to of the Crankshaft Pulley to the hole in the cover.
Step 2 below. If the engine was turned, Ford Insert bolt and finger tighten.
SST 303-1416 was removed and/or the position
of the crank and camshafts are unknown or
questionable, continue with Step 2 below.

2. Remove Valve Cover.

Refer to XXXVIII. VALVE COVER.
3. Using Ford Special Service tool 303-465, insert the
Camshaft Alignment Plate.

Special Service Tool: 303-1416 installed to secure the

Crank pulley during installation.
6. Insert Crankshaft Bolt and torque to 100 Nm (74
ft.lbs).
7. Remove Ford Special Tool 303-1416 and M6 Bolt.
8. Remove TDC Timing Peg, Ford Special Service
Tool, 303-507 and replace Bolt in timing Peg open-
NOTE ing. Torque to 20 Nm (15 ft.lbs).
The Camshaft Alignment Tool is for camshaft
alignment only. Use this tool to prevent engine
rotation can result in engine damage. The cam-
shaft timing slots are offset. If the Camshaft
Alignment Plate cannot be installed, rotate the
crankshaft one complete revolution clockwise to
correctly position the camshafts, making sure
the crank shaft is stopped by the Ford SST 303-
507.

4. If the diamond washer came off with the crankshaft

pulley, Clean and replace the Diamond Washer.
When installing the Crankshaft Pulley, ensure the miss-
ing tooth or gap in the reluctor wheel is in the 11 o’clock
position.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-20

 Group 00(L-Ford), Engine

9. Place the Crankshaft Pulley so that the missing tooth 4. To remove the water pump pulley, remove the three
in the reluctor wheel is in the 11 o’clock position and bolts on the face of the pulley.
secure with three bolts. Torque to 25 Nm (18 ft.lbs). 5. To remove the alternator, refer to XXX. ALTERNA-
10. Remove Ford Special Service tool 303-465 from the TOR.
Camshafts (if used).
11. Replace Valve Cover. INSTALLATION
Refer to XXXVIII. VALVE COVER (if removed).
1. To install the idler, secure with three bolts.
12. Reconnect Negative battery cable. Torque to 20 Nm (15 ft.lbs).
13. Start engine and verify engine is in closed loop and
2. To install the Water Pump Pulley, secure with three
no MIL light is present.
Bolts. Torque to 20 Nm (15 ft.lbs).
3. To install the Tension Pulley Bracket, secure with
XXXIII. PULLEYS/BELT- Bolts and torque to 45 Nm (33 ft.lbs.).
ALTERNATOR 4. To install the Alternator, refer to XXX. ALTERNA-
TOR.
NOTE
5. Reconnect Negative battery cable.
This application has two serpentine belts. This
instruction set covers removal and replacement 6. Start engine and verify engine is in closed loop and
of the inside belt and pulleys as shown below: no MIL light is present.

XXXIV. OIL PRESSURE SWITCH

Oil Pressure Switch

Water Pump Pulley, Alternator &
four groove Belt Assembly (Inside). REMOVAL PROCEDURE
1. Disconnect the Negative battery cable.
REMOVAL PROCEDURE
2. Locate the Oil Pressure Sender on the side of the
1. Disconnect Negative battery cable. engine block.
2. Using an open end or crescent wrench on the boss 3. Remove electrical connection from the Switch.
behind the idler pulley, release the tension on the ser-
pentine belt and remove from idler pulley. Release 4. Remove the Switch using a 15/16” wrench.
the tension, then remove the belt from the other pul-
leys.
3. To remove the Tension Pulley/Idler assembly,
remove the three bolts securing the idler.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-21

 Group 00(L-Ford), Engine

INSTALLATION PROCEDURE XXXVI. FLYWHEEL/FLEX PLATE

1. Apply Loctite 567 (or equivalent high-temp thread
locker/sealer) to the threads on the Oil Pressure
Sender.
2. Install Oil Pressure Sender. Torque until tight.
3. Plug in electrical connector.
4. Reconnect Negative battery cable.
5. Start the vehicle and let run until it reaches normal
operating temperature.
6. Check for leaks.
7. Verify engine is in closed loop and no MIL light is
present.

Flywheel

XXXV. STARTER REMOVAL PROCEDURE

REMOVAL PROCEDURE 1. Disconnect Negative battery cable.

1. Disconnect Negative battery cable. 2. Remove engine from bell housing.

2. Disconnect positive wire from starter solenoid. 3. Remove six Bolts securing Flywheel.

3. Disconnect wire from key switch on the starter. 4. Remove Flywheel.

4. Remove two Bolts securing starter to the engine and

remove starter.
INSTALLATION PROCEDURE
1. Mount Flywheel to back of crankshaft and secure
with six Bolts. Finger tighten each Bolt, then in a
INSTALLATION PROCEDURE cross pattern, torque each to 112 Nm(83 ft.lbs).
1. Secure Starter to Engine with two Bolts and torque 2. Install engine to bell housing.
to 42.5 Nm.
3. Reconnect Negative battery cable and start engine to
2. Attach wire from key switch to Starter Solenoid and ensure the starter engages properly.
torque nut to 2-3 Nm.
4. Reconnect Negative battery cable.
3. Attach positive wire to Starter Solenoid and torque
to 10 Nm. 5. Verify engine is in closed loop and no MIL light is
present.
4. Reconnect Negative battery cable.
5. Start engine and verify engine is in closed loop and
no MIL light is present.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-22

 Group 00(L-Ford), Engine

XXXVII. INJECTOR PORT PLUG REMOVAL PROCEDURE

1. Disconnect Negative battery cable.
2. Remove Oil Level Gauge (Dip Stick).
3. Remove PCV hose.
4. Remove Temperature Sensor connector.
Refer to XV. ENGINE COOLANT TEMPERATURE
NOTE SENSOR (ECT).
The Injector Port Plugs that plug the original 5. Remove Camshaft Sensor connector.
gasoline injectors should last the life of the Refer to XXIV. CAMSHAFT POSITION SENSOR.
engine. Instructions for replacement are made
available in the event replacement is required. 6. Remove VCT Electrical connector (located forward
by the oil cap).
NOTE 7. Remove Harness mounts/attachments as needed.
Keep debris or any other foreign material from
8. Remove Ignition Coils.
entering the Port Plug openings.
Refer to III. IGNITION COIL.
9. Remove 14 nuts securing Valve Cover.
INSTALLATION PROCEDURE 10. Remove Valve Cover.
1. Disconnect Negative battery cable.
2. Place Loctite 680 around the entire circumference of INSTALLATION PROCEDURE
the shaft of the plug in an unbroken line.
1. Ensure all mating surfaces on the valve cover and
3. Press port into injector opening until it is evenly and
engine block are clean and free of any debris.
fully seated.
2. Inspect Valve Cover Gaskets and replace if neces-
sary.
3. Place a bead of silicone gasket sealer, TA-30 or its
XXXVIII. VALVE COVER equivalent on the mating surfaces on bottom of the
bottom of the valve cover.
NOTE
During engine repair procedures, cleanliness is NOTE
extremely important. Any foreign material,
The working time on the gasket sealer is
including any material created while cleaning
approximately ten minutes. Be sure to seat the
gasket surfaces, that enters the oil passages,
valve cover within this period.
coolant passages or the oil pan can cause engine
failure. 4. 4. Finger tighten stud screws, then torque Screws to 9
Nm (6.6 ft.lbs.) in the following order:

Valve Cover

Top View of the Valve Cover,

with the front of the engine on the left.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-23

 Group 00(L-Ford), Engine

5. Clean any excess sealant and dispose of properly. INSTALLATION PROCEDURE

6. Install Ignition Coils. Refer to III. IGNITION COIL. 1. Install VVT and secure with bolt.
7. Install Harness mount on right forward stud (number Torque to 7.4 ft.lbs (10 Nm).
14 in the tightening sequence). 2. Install Valve Cover.
8. Install VCT Electrical connector (located forward by Refer to XXXVIII. VALVE COVER.
the oil cap).
9. Install Camshaft Sensor.
Refer to XXIV. CAMSHAFT POSITION SENSOR. XL. VALVE LASH INSPECTION
10. Install Engine Coolant Sensor. 1. Remove Valve Cover.
Refer to XV. ENGINE COOLANT TEMPERATURE Refer to XXXVIII. VALVE COVER.
SENSOR (ECT).
2. Using a large breaker or Johnson bar, rotate the
11. Install PCV hose. engine in the normal clockwise direction (facing
12. Install Oil Level Gauge (Dip Stick). engine).
13. Verfiy all electrical connectors are properly con- NOTE
nected (VCT, temperature sensor, camshaft sensor
Turn the engine clockwise only, and only use
and the ignition coils).
the crankshaft bolt.
14. Reconnect negative battery cable.
3. Use a feeler gauge to measure the clearance of each
15. Using the Spectrum Engine Monitor, clear DTC
valve and record its location.
information from the ECM and start the engine.
16. Check for leaks.
17. Verify engine is in closed loop and no MIL light is
present.

XXXIX. VARIABLE VALVE

TIMING UNIT
REMOVAL PROCEDURE Feeler Gauge Measuring Valve Lash
The acceptable clearances are:
1. Disconnect Negative battery cable.
Intake 0.003-0.012 in (0.075-0.310 mm)
2. Remove Valve Cover.
Exhaust 0.005-0.016 in (0.125-0.42 mm)
Refer to XXXVIII. VALVE COVER.
4. If any tappets do not measure within specifications,
3. Remove bolt securing the VVT and remove the
install new tappets in these locations. Refer to XLIII.
VVT.
CAMSHAFT AND/OR TAPPET REPLACEMENT
5. Reinstall Valve Cover.
Refer to XXXVIII. VALVE COVER.
6. Reconnect Negative battery cable.
7. Start engine and verify engine is in closed loop and
no MIL light is present.

Variable Valve Timing Unit and Bolt

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-24

 Group 00(L-Ford), Engine

XLI. FRONT/TIMING COVER 7. Remove three bolts (one not shown) securing the
Idler and Torque to 18.5 ft.lbs (25 Nm)
REMOVAL PROCEDURE
1. Disconnect negative battery cable.
2. Disconnect Crankshaft Position (CKP) Sensor elec-
trical connection.
3. Remove outer Pulleys and Belt.
Refer to XXXI. PULLEYS/BELT—HIGH MOUNT.
4. Remove inner Pulleys and Serpentine Belt. Refer to
XXXIII. PULLEYS/BELT—ALTERNATOR.
5. Remove Crankshaft Pulley. Pulley and bolt.
Refer to XXXII. CRANKSHAFT PULLEY.
8. Remove the Bolt securing the Pulley (if applicable).
6. Optional: Remove Crankshaft Seal using Ford Spe-
cial Service Tool 303-409.

9. Remove bolts securing Pulley.

Ford SST 303-409 being used to
remove the Crankshaft Seal.

NOTE
Use care not to damage the engine front cover
or the crankshaft when removing the seal.

Front Cover and bolts.

10. Remove bolts securing front cover to the engine, then
remove front cover.

INSTALLATION PROCEDURE
1. Clean all mating surfaces using Motorcraft® Sili-
cone Gasket Remover / ZC-30 and Metal Surface
Prep / ZC-31-A).
NOTE
Do not use metal scrapers, wire brushes, power
abrasive disks or other abrasive means to clean
sealing surfaces. These tools cause scratches
and gouges which make leak paths.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-25

 Group 00(L-Ford), Engine

NOTE
The engine front cover must be secured within
10 minutes of sealant application. If not, If the
sealant must be removed as described in the
previous step.

2. Apply a continuous bead of WSE-M4G323-A4 (Sili-

cone Gasket and Sealant / TA-30) and install front
cover.

3. Torque bolts (listed in diagram above) as follows:

Bolts 1-18 7.4 ft.lbs (10 Nm)
Bolt 19 35.4 ft.lbs. (48 Nm)
Bolts 20-22 35.4 ft.lbs. (48 Nm)

4. Install Pulley. Torque bolts to: 14.8 ft.lbs.(20 Nm)

Apply Gasket Sealer to all mating surfaces,

including the shaft above.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-26

 Group 00(L-Ford), Engine

5. Install Pulley. Torque bolts to: 8 ft.lbs. (11Nm) XLII. TIMING CHAIN & DRIVE
COMPONENTS
REMOVAL PROCEDURE
1. Remove Front Engine Cover.
Refer to XLI. FRONT COVER.

6. Install Three bolts (one not shown) securing the Idler

and Torque to 18.5 ft.lbs (25 Nm)
2. Using a small pick, release and hold the ratchet
7. Lightly lubricate the inside of the Crankshaft Seal mechanism.
with motor oil. Using Ford Special Service Tool 303-
3. While holding the ratchet mechanism in the released
096 mount the Crankshaft seal in the Front Cover.
position, compress the tensioner by pushing the tim-
ing chain arm toward the tensioner.
4. Insert the holding pin into the hole to retain the ten-
sioner.

Mounting the Crankshaft Seal on the front cover.

8. Install Crankshaft Pulley.
Refer to XXXII. CRANKSHAFT PULLEY.
9. Reconnect Negative battery cable.
5. Remove the two bolts securing the Tensioner
10. Start engine and verify engine is in closed loop and
no MIL light is present.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-27

 Group 00(L-Ford), Engine

6. Remove the Timing Chain.

3. Install Timing Chain.

7. Remove Two Screws securing the Timing Chain
Tensioner Arm and remove the Tensioner Arm and
Timing Chain Guide

INSTALLATION PROCEDURE
1. Align the Camshafts using Ford SST 303-465.
Refer to XLIII. CAMSHAFT AND/OR TAPPET
REPLACEMENT

NOTE
If the timing chain plunger and ratchet assem-
bly are not pinned in the compressed position,
follow the next four steps.

NOTE
The Camshaft Alignment Plate is for camshaft
alignment only. Using this tool to prevent
engine rotation can result in engine damage.
Use the flats on the camshaft to prevent cam-
shaft rotation.
2. Install the Tensioner Arm and Timing Chain Guide NOTE
and secure with two bolts. Torque to 78.4 ft.lbs (10
Do not compress the ratchet assembly.
Nm).
This will damage the ratchet assembly. Using
the edge of a vise, compress the timing chain
tensioner plunger.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-28

 Group 00(L-Ford), Engine

XLIII. CAMSHAFT AND/OR

TAPPET REPLACEMENT
NOTE
During engine repair procedures, cleanliness is
extremely important. Any foreign material
(including any material created while cleaning
gasket surfaces) that enters the oil passages,
coolant passages or the oil pan can cause engine
failure.
4. Using a small pick, push back and hold the ratchet Failure to follow the camshaft tightening proce-
mechanism. dure can result in damage to the camshafts.
Lubricate the camshaft journals and camshaft
bearing caps with clean engine oil.

1. Disconnect Negative Battery Cable.

2. Check the Valve Lash.
Refer to XL. VALVE LASH INSPECTION.
3. Remove the high mount Pulleys and belt.

NOTE
5. While holding the ratchet mechanism, push the This application has two serpentine belts.
ratchet arm back into the tensioner housing. Install a
holding pin into the hole in the tensioner housing to
hold the ratchet assembly and the plunger in during
installation.

6. Replace the timing chain plunger and secure with

two bolts. Torque to 7.4 ft.lbs. (10 Nm).
Next, remove the holding pin to release the piston
and tighten the chain.
7. Install Front Engine Cover.
Refer to XLI. FRONT COVER.
8. Reconnect Negative battery cable.
9. Start engine and verify engine is in closed loop and
High Mount Fan six groove Belt and Pulley assembly
no MIL light is present.
(Outside).

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-29

 Group 00(L-Ford), Engine

4. Using an open end or crescent wrench on the boss 9. To remove the Water Pump Pulley, remove the three
behind the Idler Pulley, release the tension on the Bolts on the face of the Pulley.
Serpentine Belt and remove the Belt from the Idler 10. Remove the outer Crank Pulley by removing the
Pulley and all other Pulleys. three Bolts securing the outer Crank Pulley to the
5. Remove the three Bolts securing the Fan and Bracket inner Crank Pulley.
assembly.
11. Remove the Bolt in the side of the engine (as shown
6. Remove the Bolt securing the Pulley on the Bracket in the illustration) and insert Ford Special Service
assembly, then remove the entire assembly. Tool, 303-507.

Install Special Service Tool: 303-507.

12. Using a large breaker or Johnson bar, rotate the
engine in the normal direction until cylinder 1 is at
TDC (it will stop when it hits the Special Service
Tool, 303-507.

NOTE
The Crankshaft must remain in the TDC posi-
tion during removal of the Pulley Bolt or dam-
Water Pump Pulley, Alternator & four groove Belt
age to the engine can occur. Therefore, the
Assembly (Inside).
Crankshaft Pulley must be held in place with
7. Using an open end or crescent wrench on the boss the Crankshaft Damper Holding Tool, and the
behind the Idler Pulley, release the tension on the Bolt should be removed using an air impact
Serpentine Belt and remove from Idler Pulley. wrench (1/2-in drive minimum), breaker or
Release the tension, then remove the Belt from the Johnson bar.
other Pulleys.
13. Install Ford Special Service Tool 303-1416 to secure
8. To remove the Tension Pulley/Idler assembly, the crank pulley: Using an M6 bolt, align the hole at
remove the three Bolts securing the Idler. the bottom of the Crankshaft Pulley to the hole in the
cover. Insert Bolt and finger tighten.

Install Ford Special Service Tool 303-1416

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-30

 Group 00(L-Ford), Engine

14. Remove the Crankshaft Pulley Bolt using an air 28. Remove Valve Cover.
impact wrench and remove Pulley.

NOTE
The Crankshaft Pulley Diamond Washer may
come off with the Crankshaft Pulley.

15. Remove SST 303-1416.

16. Remove PCV hose.
Valve Cover
29. Disconnect Crankshaft Position (CKP) Sensor elec-
trical connection on side of engine.
30. Optional: If desired, remove Crankshaft Seal using
Ford Special Service Tool 303-409.

Coolant Temperature Sensor

17. Locate the Engine Coolant Temperature Sensor on
the top of the engine.
18. Remove electrical connector.
19. Using an extra deep 24mm socket or a Ford Special Ford SST 303-409 being used.
Service tool, remove the sensor.
NOTE
20. Remove Camshaft Sensor connector.
Use care not to damage the engine front cover
or the Crankshaft when removing the seal.

Camshaft Sensor
21. Remove the Bolt securing the Camshaft Sensor.
22. Remove VCT Electrical connector (located forward Front Cover and Bolts.
by the oil cap). 31. Remove Bolts securing Front Cover to the engine,
23. Remove electrical connector on each Ignition Coil. then remove Front Cover.
24. Remove Harness mounts/attachments as needed. NOTE
25. Remove Bolt securing each Ignition Coil. Use care in removing the Front Cover and avoid
26. Gently remove the Ignition Coil by pulling while using screwdrivers or other instruments that
lightly twisting back and forth. might damage the lip of the Front Cover.

27. Remove 14 nuts securing Valve Cover.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-31

 Group 00(L-Ford), Engine

37. Remove Two Screws securing the Timing Chain

Tensioner Arm and remove the Tensioner Arm and
Timing Chain Guide.

32. Using a small pick, release and hold the ratchet

mechanism.
33. While holding the ratchet mechanism in the released 38. Using the flats of the camshaft, rotate the camshaft to
position, compress the Tensioner by pushing the place the cam lobe at base circle, with the lobe
Timing Chain Arm toward the Tensioner. pointed away from the tappet.
34. Insert the holding pin into the hole to retain the Ten- 39. Use a feeler gauge to measure the clearance of each
sioner. valve and record its location.
40. Repeat to measure all of the lobe/tappet clearances.

NOTE
Failure to follow the camshaft loosening proce-
dure can result in damage to the camshafts.
Mark the location and orientation of each cam-
shaft bearing cap.
Mark the location of the camshafts prior to
removal.
35. Remove the two Bolts securing the Tensioner

36. Remove the Timing Chain. Camshaft Bolt Loosening Sequence

41. Loosen the camshaft bearing cap bolts, in sequence
(as shown above), one turn at a time until all tension
is released from the camshaft bearing caps.

NOTE
If the camshafts and valve tappets are to be
reused, mark the location of the valve tappets to
make sure they are assembled in their original
positions.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-32

 Group 00(L-Ford), Engine

42. Remove camshaft bearing caps and camshafts. INSTALLATION PROCEDURE

NOTE NOTE
The nominal clearance is: Failure to follow the camshaft tightening proce-
Intake: 0.25 mm (0.0095 in). dure can result in damage to the camshafts.
Exhaust: 0.36 mm (0.0142 in).
Lubricate the camshaft journals and camshaft
The acceptable tappet to valve clearance clearances after bearing caps with clean engine oil.
being fully installed are:
Rotate the crankshaft clockwise 90 degrees so the crank-
Intake 0.075-0.310 mm (0.003-0.012 in) shaft contacts the Timing Peg, Crankshaft TDC 303-507.
Exhaust 0.125-0.42 mm (0.005-0.016 in)

NOTE
Select tappets using this formula: ideal tappet
thickness = measured clearance + the existing
tappet thickness - nominal clearance.
The number on the valve tappet only reflects
the digits that follow the decimal. For example,
a tappet with the number 0.650 has the thick-
ness of 3.650 mm.
NOTE
Install the camshafts with the alignment slots in
the camshafts lined up so the Camshaft Align-
ment Plate can be installed without rotating the
camshafts. Make sure the lobes on the No. 1 cyl-
inder are in the same position as noted in the
removal procedure. Rotating the camshafts
when the timing chain is removed, or installing
the camshafts 180 degrees out of position can
43. Visually inspect the Tappets for wear or damage.
cause severe damage to the valves and pistons.
44. Select the closest tappet size to the ideal tappet thick-
ness available and mark the installation location. 1. Apply the specified lubricant to the specified compo-
nent (Motorcraft® SAE 5W-20 Premium Synthetic
Blend Motor Oil / XO-5W20-QSP)

NOTE
The Camshaft Alignment Tool is for camshaft
alignment only. Using this tool to prevent
engine rotation can result in engine damage.

2. Install Special Service Tool: 303-465. If necessary,

rotate Camshafts to align the slots.

45. If necessary, replace any tappets with the correct tap-

pets selected during the valve clearance check.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-33

 Group 00(L-Ford), Engine

5. Remove SST 303-507.

3. Tighten the Camshaft Bearing Cap Bolts one turn at

a time, until finger-tight, then torque as follows: NOTE
Rotating the crankshaft will position all of the
pistons below the deck of the cylinder block and
allow the camshafts to be installed and the valve
clearance checked without the possibility of
damage to the valves or pistons.

6. Using the crankshaft bolt and washer, rotate the

crankshaft clockwise 270 degrees until the paint
mark is at the 9 o'clock position.

Camshaft Bearing Cap Bolt tightening order.

Torque:
Stage 1: 5.2 ft..lbs. (7 Nm)
Stage 2: 11.8 ft. lbs. (16 Nm)

NOTE
If any new parts are being installed (cylinder
head, valves, tappets, camshafts) it is necessary
to check the valve clearance, follow the next
steps exactly or serious damage to the engine 7. Install Ford Special Service Tool: 303-507.
may occur.

NOTE
4. Place a paint mark on the crankshaft at the 12 o'clock Rotating the crankshaft will position the engine
position, as shown above. at TDC and allow you to install the camshafts in
the same position as noted during the disassem-
bly.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-34

 Group 00(L-Ford), Engine

8. Install the Tensioner Arm and Timing Chain Guide NOTE

and secure with two Bolts. Do not compress the ratchet assembly. This will
Torque to 78.4 ft.lbs (10 Nm). damage the ratchet assembly. Using the edge of
a vise, compress the Timing Chain Plunger.

10. Using a small pick, push back and hold the ratchet
mechanism.
11. While holding the ratchet mechanism, push the
ratchet arm back into the Tensioner housing. Install a
holding pin into the hole in the Tensioner housing to
hold the ratchet assembly and the plunger in during
installation.

9. Ensure the Camshafts and Crankshaft are in proper

alignment using the Ford SSTs 303-465 and 303-
507, then install Timing Chain.

12. Replace the Timing Chain Plunger and secure with

two Bolts. Torque to 7.4 ft.lbs. (10 Nm).
Next, remove the holding pin to release the piston
and tighten the Chain.
NOTE 13. Clean all mating surfaces using Motorcraft® Sili-
If the Timing Chain Plunger and ratchet assem- cone Gasket Remover/ZC-30 and Metal Surface
bly are not pinned in the compressed position, Prep/ZC-31-A).
follow the next four steps.
NOTE
Do not use metal scrapers, wire brushes, power
abrasive disks or other abrasive means to clean
sealing surfaces. These tools cause scratches
and gouges which make leak paths.
The engine Front Cover must be secured within
10 minutes of sealant application. If not, If the
sealant must be removed as described in the
previous step.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-35

 Group 00(L-Ford), Engine

14. Apply a continuous bead of WSE-M4G323-A4 (Sili-

cone Gasket and Sealant / TA-30) and install Front
Cover.

15. Torque bolts (listed in diagram above) as follows:

Bolts 1-18 7.4 ft.lbs (10 Nm)
Bolt 19 35.4 ft.lbs. (48 Nm)
Bolts 20-22 35.4 ft.lbs. (48 Nm)
16. If the Crankshaft Seal was removed, lightly lubricate
the inside of the Crankshaft Seal with motor oil.
Using Ford Special Service Tool 303-096 mount the
Crankshaft seal in the Front Cover.

Apply Gasket Sealer to all mating surfaces, including

Mounting the Crankshaft Seal on the Front Cover.
the shaft above.

17. Install Pulley on the Water Pump.

Torque bolts to: 14.8 ft.lbs. (20 Nm).

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-36

 Group 00(L-Ford), Engine

18. Install Tensioner. 20. Using Ford Special Service tool 303-465, insert the
Torque bolts to: 8 ft.lbs. (11 Nm). Camshaft Alignment Plate.

NOTE
The Camshaft Alignment Tool is for Camshaft
alignment only. Use this tool to prevent engine
rotation can result in engine damage. The Cam-
19. Install three Bolts (one not shown) securing the Idler shaft timing slots are offset. If the Camshaft
and Torque to 18.5 ft.lbs (25 Nm). Alignment Plate cannot be installed, rotate the
Crankshaft one complete revolution clockwise
to correctly position the Camshafts, making
! WARNING
sure the Crank Shaft is stopped by the Ford
Do not install the Crankshaft Pulley Bolt with- SST 303-507.
out first installing the special tools as instructed
in this procedure. The Crankshaft Pulley and 21. If the Diamond Washer came off with the Crankshaft
the Crankshaft Timing sprocket are not keyed Pulley, Clean and replace the Diamond Washer.
to the Crankshaft. The Crankshaft, the Crank-
shaft Sprocket and the Pulley are fitted together
by friction. For that reason, the Crankshaft
Sprocket is also unfastened if the Crankshaft
Pulley Bolt is loosened. Before any repair
requiring loosening or removal of the Crank-
shaft Pulley Bolt, the Crankshaft and Cam-
shafts must be locked in place by the special
service tools, otherwise severe engine damage
can occur.
Arrow depicting Diamond Washer.
NOTE
Failure to position the No. 1 piston at TDC can
result in damage to the engine. Avoid rotating
the engine. If the engine is turned, turn in the
normal direction of rotation (clockwise as
viewed from the front/fan side) only.

NOTE
The Crankshaft TDC Timing Peg will contact
the Crankshaft and prevent it from turning past
TDC. However, the Crankshaft can still be
rotated in the counterclockwise direction. The
Crankshaft must remain at the TDC position When installing the Crankshaft Pulley, ensure the miss-
during the Crankshaft Pulley installation. ing tooth or gap in the reluctor wheel is in the 11 o’clock
position.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-37

 Group 00(L-Ford), Engine

22. Place the Crankshaft Pulley so that the missing tooth

in the reluctor wheel is in the 11 o’clock position.
23. Mount Ford SST 303-1416 using an M6 bolt, align
the hole at the bottom of the Crankshaft Pulley to the
hole in the cover. Insert Bolt and finger tighten, then
torque to 100 Nm (74 ft.lbs).

Top View of the Valve Cover, with the front of the

engine on the left. Torque the Valve Cover Screws in the
order as pictured above.
31. Clean any excess sealant and dispose of properly.
Special Service Tool: 303-1416 installed to secure the
32. Insert each Ignition Coil into the opening on the Cyl-
Crank Pulley during installation. inder Head, ensuring the boot is properly placed on
24. Insert Crankshaft Bolt Remove Ford Special Tool top of the Spark Plug and verify the coil is flush with
303-1416 and M6 Bolt. top of the Cylinder Head.
25. Remove TDC Timing Peg, Ford Special Service 33. Secure Ignition Coils with Bolts.
Tool, 303-507 and replace Bolt in timing Peg open- Torque to 10 Nm (7.4 ft. lbs.).
ing. Torque to 20 Nm (15 ft.lbs). 34. Reconnect electrical connector to each Coil.
26. Remove Ford Special Service tool 303-465 from the 35. Install VCT Electrical connector (located forward by
Camshafts. the oil cap).
27. Install VCT and secure with bolt. 36. Mount Camshaft Sensor.
Torque to 7.4 ft.lbs (10 Nm). Secure with Bolt and torque to 7 Nm (5.2 ft.lbs.).
28. Inspect Valve Cover Gaskets and replace if neces-
sary and ensure all mating surfaces on the Valve NOTE
Cover and engine block are clean and free of any Spacing is important for the Sensor. Make sure
debris. the Sensor is properly positioned and seated.
29. Place a bead of silicone gasket sealer, TA-30 or its
37. Connect electrical connect to the Camshaft Sensor.
equivalent on the mating surfaces on bottom of the
bottom of the Valve Cover. 38. Apply a minimal amount of pipe thread sealer to
threads on the Engine Coolant Temperature Sensor.
NOTE Remove any excess sealer on threads or the Sensor
The working time on the gasket sealer is and install Engine Coolant Sensor (ECT).
approximately ten minutes. Be sure to seat the Torque to 12 Nm (106 in.lbs.).
valve cover within this period. 39. Reconnect ECT electrical connector.
30. Mount the Valve Cover, finger tighten stud screws, 40. Install PCV hose.
then torque Screws to 9 Nm (6.6 ft.lbs.) in the fol- 41. Install Oil Level Gauge (Dip Stick).
lowing order:
42. Verify all electrical connectors are properly con-
nected (VCT, temperature sensor, camshaft sensor
and the ignition coils).
43. Mount the outer Crankshaft Pulley and secure with
three Bolts. Torque to 25 Nm (18 ft.lbs).

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-38

 Group 00(L-Ford), Engine

44. If the Alternator was removed, reinstall. NOTE

Refer to XXX. ALTERNATOR. During engine repair procedures, cleanliness is
45. Place the Serpentine Belt on all inner Pulleys, except extremely important. Any foreign material
the Tensioner Pulley. Using an open end or crescent (including any material created while cleaning
wrench on the boss behind the Idler Pulley, move the gasket surfaces) that enters the oil passages,
Tensioner back and place the Serpentine over the coolant passages or the oil pan may cause
Pulley, then release the tension. engine failure.
46. Install the three Bolts at the top of the Fan Bracket NOTE
and secure the Bracket to the Engine. Aluminum surfaces are soft and can be
Torque Bolts to 33-69 ft.lbs (45-49 Nm). scratched easily. Never place the cylinder head
47. Install the Idler for the outer Belt and secure with gasket surface, unprotected, on a bench surface.
three Bolts. Torque to 20 Nm (15 ft.lbs).
1. Remove the Valve Cover, Camshafts and other com-
48. Place the outer Serpentine Belt on all Pulleys, except ponents as described in XLIII. CAMSHAFT AND/OR
the Tensioner Pulley. Using an open end or crescent TAPPET REPLACEMENT.
wrench on the boss behind the Idler Pulley, move the
Tensioner back and place the Serpentine over the 2. Remove the Intake Manifold.
Pulley, the release the tension. Refer to XVI. INTAKE MANIFOLD.
49. Reconnect Negative Battery Cable. 3. Remove the Intake Manifold.
Refer to XVII. EXHAUST MANIFOLD.
50. Using the Spectrum Engine Monitor, clear DTC
information from the ECM. Start the engine.
51. Check for leaks.
52. Verify engine is in closed loop and no MIL light is
present.

XLIV. CYLINDER HEAD

REMOVAL
NOTE
Do not loosen or remove the crankshaft pulley 4. Remove bolts securing the cylinder to the engine
bolt without first installing the special tools as block.
instructed in this procedure. The crankshaft
pulley and the crankshaft timing sprocket are
not keyed to the crankshaft. The crankshaft, the INSTALLATION
crankshaft sprocket and the pulley are fitted
NOTE
together by friction, using diamond washers
between the flange faces on each part. For that Do not use metal scrapers, wire brushes, power
reason, the crankshaft sprocket is also unfas- abrasive discs or other abrasive means to clean
tened if the pulley bolt is loosened. Before any the sealing surfaces. These tools cause scratches
repair requiring loosening or removal of the and gouges that make leak paths. Use a plastic
crankshaft pulley bolt, the crankshaft and cam- scraping tool to remove all traces of the head
shafts must be locked in place by the special ser- gasket.
vice tools, otherwise severe engine damage can
1. Clean the cylinder head-to-cylinder block mating
occur.
surface of both the cylinder head and the cylinder
block using Motorcraft Metal Surface Prep / ZC- 31-
A Material and Silicone Gasket Remover / ZC- 30.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-39

 Group 00(L-Ford), Engine

2. Check the cylinder head distortion. XLV. CYLINDER HEAD DISTORTION

Refer to: XLV. CYLINDER HEAD DISTORTION.

3. Clean the cylinder head bolt holes in the cylinder

block. Make sure all coolant, oil or other foreign
material is removed.
4. Apply the specified sealant to the specified compo-
nent. Silicone Gasket and Sealant / TA-30

NOTE
Make sure all cylinder head surfaces are clear
of any gasket material, silicone sealant, oil and
coolant. The cylinder head surface must be
clean and dry before running a flatness check.

NOTE
Use a Straightedge that is calibrated by the
manufacturer to be flat within 0.005 mm
(0.0002 in) per running foot of length, such as
Snap-On® GA438A or equivalent. For exam-
ple, if the Straightedge is 61 cm (24 in) long, the
machined edge must be flat within 0.010 mm
(0.0004 in) from end to end.

1. Using a Straightedge and a Feeler Gauge Set, inspect

the cylinder head for flatness in the sequence shown
in the illustration above.

NOTE XLVI. VALVE SPRINGS

The cylinder head bolts are torque- toyield and
must not be reused. New cylinder head bolts REMOVAL
must be installed. Torque as follows:
NOTE
Stage 1: 7 Nm During engine repair procedures, cleanliness is
Stage 2: 15 Nm extremely important. Any foreign material
Stage 3: 45 Nm (including any material created while cleaning
Stage 4: 90° gasket surfaces) that enters the oil passages,
Stage 5: Turn an additional 90° coolant passages or the oil pan can cause engine
5. Reinstall the Valve Cover, Camshafts and other com- failure.
ponents as described in XLIII. CAMSHAFT AND/OR
TAPPET REPLACEMENT.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-40

 Group 00(L-Ford), Engine

1. Remove the Valve Cover, Camshafts and other com- INSTALLATION

ponents as described in XLIII. CAMSHAFT AND/OR
1. Visual check. Install new parts as necessary.
TAPPET REPLACEMENT.

NOTE
Use compressed air at 7 to 10 bars (100-150 psi).
Do not disconnect the compressed air from the
cylinder until the valve spring, valve spring
retainer and valve collets is installed. Any loss
of air pressure will allow the valve to fall into
the cylinder.

NOTE
Use a small screwdriver and multipurpose
grease to remove the valve collets.
2. Disconnect the compressed air supply.
2. Connect the compressed air supply to cylinder No. 1
NOTE
3. Remove the valve collets, valve spring retainers and Use a small screwdriver and multi-purpose
the valve springs. Use Special Service Tools 3030- grease to install the valve collets.
300, 303-350, 303-472 and clean oil.
NOTE
Check the seating of the valve collets. Install the
valve springs, valve spring retainers and the
valve collets. Use Special Service Tools: 303-
300, 303-350 and 303-472.

3. Repeat the appropriate removal and installation steps

for all of the other cylinders.
4. Reinstall the Valve Cover, Camshafts and other com-
ponents as described in XLIII. CAMSHAFT AND/OR
TAPPET REPLACEMENT

XLVIII.VALVE GUIDE INNER

DIAMETER CHECK
NOTE
Refer to the appropriate Section 303-01 for the
specification.

4. Inspect springs.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-41

 Group 00(L-Ford), Engine

NOTE 2. Remove Valve Springs.

Valve guides tend to wear in an hourglass pat- Refer to XLVI. VALVE SPRINGS.
tern. The ball gauge can be inserted into the 3. Visually inspect and remove seals as necessary using
combustion chamber side of the valve guide, if Special Service Tools: 303-468, 307-005.
necessary.

1. Use a ball gauge to determine the inside diameter of

the valve guides in 2 directions at the top, middle and
bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install
a new cylinder head assembly.

XLIX. VALVE STEM DIAMETER

INSTALLATION
CHECK
NOTE
NOTE Use the protector provided with the replace-
Refer to the appropriate Section 303-01 for the ment kit to prevent damage to the valve seals.
specification.

1. Measure the diameter of each intake and exhaust

valve stem at the points shown. Verify the diameter 1. Visually inspect and install new seal as necessary
is within specification. using Special Service Tools: 303-468, 307-005 and
Purpose Grease Spray / XL-5.

L. VALVE STEM SEALS

REMOVAL
NOTE
During engine repair procedures, cleanliness is
extremely important. Any foreign material
(including any material created while cleaning
gasket surfaces) that enters the oil passages,
coolant passages or the oil pan can cause engine 2. Replace Valve Springs.
failure. Refer to XLVI. VALVE SPRINGS.

1. Remove the Valve Cover, Camshafts and other com- 3. Replace the Valve Cover, Camshafts and other com-
ponents as described in XLIII. CAMSHAFT AND/OR ponents as described in XLIII. CAMSHAFT AND/OR
TAPPET REPLACEMENT. TAPPET REPLACEMENT.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-42

 Group 00(L-Ford), Engine

LI. OIL PAN INSTALLATION

REMOVAL NOTE
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 plas-
tic scraping tool to remove traces of sealant.

1. Clean all mating surfaces using Motorcraft Silicone

Gasket Remover / ZC-30 and Motorcraft Metal Sur-
face Prep / ZC-31-A.

NOTE
To prevent damage to the transmission, do not
loosen the transmission-to-engine bolts more
than 5 mm (0.19 in). Loosen 5 mm (0.19 in).

2. Apply Silicone Gasket and Sealant / TA-30 and

attach oil pan to the bottom of the engine.

NOTE
If the oil pan is not secured within 10 minutes of
sealant application, the sealant must be
removed and the sealing area cleaned with
1. Drain the oil. metal surface prep. Allow to dry until there is
2. Remove bolts securing Oil Pan. no sign of wetness, or 10 minutes, whichever is
longer. Failure to follow this procedure can
cause future oil leakage. Apply a continuous
bead of the specified diameter from the speci-
fied tube.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-43

 Group 00(L-Ford), Engine

3. Finger tight bolts. LII. OIL PUMP SCREEN AND

PICKUP TUBE REMOVAL
REMOVAL
1. Remove Oil Pan. Refer to XLVIII. OIL PAN.

NOTE
The engine front cover-to-oil pan bolts must be
tightened first to align the front surface of the
oil pan flush with the front surface of the engine
block. 2. Remove Bolts.

3. Remove gasket.

INSTALLATION

4. Torque bolts to 10 Nm as shown above, then repeat

to 20 Nm.
5. Refill oil.

1. Replace gasket.

2. Torque bolts to 10 Nm
3. Replace Oil pan. Refer to XLVIII. OIL PAN.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-44

 Group 00(L-Ford), Engine

L. OIL PUMP 4. Remove Oil Pan. Refer to XLVIII. OIL PAN.

REMOVAL
1. Remove Timing Cover. Refer to XLII. TIMING
CHAIN & DRIVE COMPONENTS.

5. Remove Oil Pick up tube

2. Drain the oil.

6. Remove bolts.

3. Remove bolt.

7. Remove bolt.

8. Remove bolts securing oil pump and remove pump.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-45

 Group 00(L-Ford), Engine

INSTALLATION LIII. OIL FILTER ADAPTER

NOTE REMOVAL
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 plas-
tic scraping tool to remove traces of sealant.

1. Clean all mating surfaces using Motorcraft Silicone

Gasket Remover / ZC-30 and Metal Surface Prep /
ZC-31-A)

1. Remove Oil Filter.

2. Torque bolts securing oil pump as follows:

Stage 1: 10 Nm
Stage 2: 20 Nm
Torque: 25 Nm 2. Remove Oil Filter Adapter.

3. Hook the tensioner spring around the shoulder bolt 3. Remove Gasket
and Torque bolts to 10 Nm.
4. Replace Oil Pan. Refer to XLVIII. OIL PAN. INSTALLATION
5. Remove Timing Cover. Refer to XLII. TIMING
CHAIN & DRIVE COMPONENTS.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-46

 Group 00(L-Ford), Engine

1. Replace Gasket 2. Mark the balancer unit and shafts on the top for refer-
ence that the balancer unit is at TDC.

2. Replace Oil Filter Adapter.

NOTE
Due to the precision interior construction of the
balancer unit, it should not be disassembled.

3. Remove the adjustment shims from the seat faces of

the balancer unit.
NOTE
Visually inspect the balancer unit gear for dam-
age and verify that the shaft turns smoothly.
If there is any damage or malfunction, replace
3. Replace Oil Filter. the balancer unit.

LVI. BALANCE SHAFT BACKLASH

4. Install the master adjustment shims (No. 50) on the

seat faces of the balancer unit.
1. Install Special Service Tool: 303-507. Rotate the 5. With the balancer unit shaft marks at the TDC posi-
crankshaft slowly clockwise until the crankshaft bal- tion, slowly install the balancer unit to the cylinder
ance weight is up against the Crankshaft TDC (top block to avoid interference between the crankshaft
dead center) Timing Peg. The engine is now at TDC. drive gear and the balancer unit driven gear.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-47

 Group 00(L-Ford), Engine

6. Torque bolts as follows: NOTE

Stage 1: 25 Nm For an accurate measurement while measuring
Stage 2: 52 Nm the gear backlash, insert a screwdriver as
shown into the crankshaft No. 1 crankweight
area and set both the rotation and the thrust
direction with the screwdriver, using a prying
action as shown.

12. Position as shown. Measure the gear backlash.

13. Use Special Service Tool: 100-002.
14. Position the Dial Indicator Gauge with Holding Fix-
ture (1) on the Allen wrench 80 mm (3.149 in) above
the driven gear shaft center (2) on the balancer unit.
7. Remove Special Service Tool: 303-507. 15. Rotate the crankshaft clockwise and measure the
8. Rotate the crankshaft to confirm that there are no backlash at all of the following 6 positions: 10
meshing problems between the balancer unit gear degrees, 30 degrees, 100 degrees.
and the crankshaft gear. 16. 190 degrees, 210 degrees and 280 degrees.

9. Install Special Service Tool: 303-507.

10. Rotate the crankshaft slowly clockwise until the
crankshaft balance weight is up against the Crank-
shaft TDC Timing Peg. The engine is now at TDC.
11. Remove Special Service Tool: 303-507.

NOTE
Measure the backlash and verify that it is
within specified range at all of the following 6
positions: 10 degrees, 30 degrees, 100 degrees,
190 degrees, 210 degrees and 280 degrees. It will
be necessary to reset the measuring equipment
between measurements.

NOTE
The measurement must be taken with the Dial
Indicator Gauge with Holding Fixture, a 5-mm
Allen wrench and worm clamp set up as shown.
Mark the Allen wrench with a file 80 mm (3.149
in) above the driven gear shaft center. Make
sure the worm clamp and Allen wrench are not
touching the balance shaft housing.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-48

 Group 00(L-Ford), Engine

NOTE
If maximum backlash exceeds 0.101 mm (0.0039
in), install a new balancer unit.

17. Using the backlash measurement, select the proper

shims from the Adjustment Shim Selection Table.
18. Remove the balancer unit from the cylinder block.
19. Install the selected adjustment shims on the seat
faces of the balancer unit.
20. Install Special Service Tool: 03-507.
22. With the balancer unit shaft marks at the TDC posi-
21. Rotate the crankshaft slowly clockwise until the
tion, slowly install the balancer unit to the cylinder
crankshaft balance weight is up against the Crank-
block to avoid interference between the crankshaft
shaft TDC Timing Peg. The engine is now at TDC.
drive gear and the balancer unit driven gear.

23. Torque the bolts as follows:

Stage 1: 25 Nm
Stage 2: 52 Nm

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-49

 Group 00(L-Ford), Engine

24. Remove Special Service Tool 303-507.

NOTE
Measure the backlash and verify that it is
within specified range at all of the following 6
positions: 10 degrees, 30 degrees, 100 degrees,
190 degrees, 210 degrees and 280 degrees. It will
be necessary to reset the measuring equipment
between measurements.

NOTE
The measurement must be taken with the Dial
Indicator Gauge with Holding Fixture, a 5-mm
Allen wrench and worm clamp set up as shown. LVII. ENGINE, LOWER DISASSEMBLY
Mark the Allen wrench with a file 80 mm (3.149
in) above the driven gear shaft center. Make
sure the worm clamp and Allen wrench are not ! WARNING
touching the balance shaft housing.
Before beginning any service procedure in this
section, refer to Safety Warnings in section 100-
NOTE
00 General Information. Failure to follow this
For an accurate measurement while measuring
instruction may result in serious personal
the gear backlash, insert a screwdriver as
injury.
shown into the crankshaft No. 1 crankweight
area and set both the rotation and the thrust 1. Remove Cylinder Head.
direction with the screwdriver, using a prying Refer to XLIV. CYLINDER HEAD.
action as shown.

25. Position as shown. Measure the gear backlash using

Special Service Tool: 100-002.
26. Position the Dial Indicator Gauge with Holding Fix-
ture (1) on the Allen wrench 80 mm (3.149 in) above
the driven gear shaft center (2) on the balancer unit.
27. Rotate the crankshaft clockwise and measure the
backlash at all of the following 6 positions: 10
degrees, 30 degrees, 100 degrees, 190 degrees, 210
degrees and 280 degrees. 2. Inspect for damage to the cylinder walls.
28. If the backlash exceeds the specified range of 0.005 3. Clean the block of any deposits using an abrasive
to 0.101 mm (0.00019 to 0.0039 in), install a new pad.
balancer unit and repeat the procedure.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-50

 Group 00(L-Ford), Engine

4. Remove the bolts in the sequence shown above.

NOTE NOTE
Clearly mark the connecting rods, connecting If the main bearings are being reused, mark
rod caps and connecting rod bearings in numer- them in order for correct orientation and reas-
ical order for correct orientation for reassem- sembly.
bly.

NOTE
If the main bearings are being reused, mark
them in order for correct orientation and reas-
sembly.
The center bulkhead has the thrust bearing.
NOTE
Do not scratch the cylinder walls or crankshaft
journals with the connecting rod.
Mark the position of the parts, so they can be
installed in their original positions.

NOTE
If the oil squirters are being reused, mark them
in order for correct location during reassembly.
The front bulkhead does not have an oil squirter.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-51

 Group 00(L-Ford), Engine

5. Inspect the pistons. 2. Position a piece of Plastigage across the crankshaft

6. Inspect the cylinder bore taper. main bearing surface.

NOTE
LVIII. CYLINDER BLOCK Do not turn the crankshaft while carrying out
this procedure.
DISTORTION
3. Install and tighten to specifications, then remove the
crankshaft main bearing cap.

NOTE 4. Measure the Plastigage to get the crankshaft main

Use a Straightedge that is calibrated by the bearing clearance.
manufacturer to be flat within 0.005 mm 5. The Plastigage should be smooth and flat. A chang-
(0.0002 in) per running foot of length, such as ing width indicates a tapered or damaged crankshaft
Snap-On GA438A or equivalent. For example, or crankshaft bearing.
if the Straightedge is 61 cm (24 in) long, the
machined edge must be flat within 0.010 mm
(0.0004 in) from end to end.
LX. CYLINDER BORE TAPER
1. Use a Straightedge and a Feeler Gauge Set to inspect
the cylinder block for flatness. NOTE
Refer to the appropriate Section 303-01 for the
specification.
LIX. CRANKSHAFT MAIN BEAR-
ING JOURNAL CLEARANCE
NOTE
Crankshaft main bearing journals must be
within specifications before checking journal
clearance.

1. Remove the crankshaft main bearing cap and crank-

shaft main bearing.

1. Measure the cylinder bore at the top, middle and bot-

tom of piston ring travel in 2 directions as indicated.
Verify the cylinder bore is within the wear limit. The
difference indicates the cylinder bore taper. If the
cylinder bore taper does not meet specification, bore
the cylinder to the next oversize limit.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-52

 Group 00(L-Ford), Engine

LXI. BEARING INSPECTION 2. Position a piece of Plastigage across the bearing sur-
face.

NOTE
Do not turn the crankshaft during this step.

3. Install and tighten to specifications, then remove the

connecting rod bearing cap.

Identifying Wear Patterns

1. Cratering - fatigue failure
2. Spot glazing - incorrect seating
3. Scratching - dirty engine oil 4. Measure the Plastigage to get the connecting rod
4. Base exposed - poor lubrication bearing journal clearance. The Plastigage should be
smooth and flat. A changing width indicates a
5. Both edges worn - journal damaged
tapered or damaged connecting rod or connecting rod
6. One edge worn - journal tapered or bearing not bearing.
seated

LXIII. PISTON
LXII. CONNECTING ROD BEARING
JOURNAL CLEARANCE DISASSEMBLY
1. Remove the wrist pin.
NOTE
Refer to the appropriate Section 303-01 for the
specification.

NOTE
The crankshaft connecting rod journals must be
within specifications to check the connecting
rod bearing journal clearance.

1. Remove the connecting rod bearing cap and connect-

ing rod bearing.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-53

 Group 00(L-Ford), Engine

2. Remove the connecting rod. 3. Apply a coat of clean oil.

4. Insert wrist pin.

ASSEMBLY
NOTE
If the piston and connecting rod are to be rein-
stalled, they must be assembled in the same ori-
entation. Mark the piston orientation to the
connecting rod for reassembly.

1. Clean and inspect the piston.

NOTE 5. Add a light coat of oil to the piston rings.

Align the piston-to-connecting rod orientation
marks made during disassembly.

NOTE
The piston compression upper and lower rings
should be installed with the paint mark on the
outside diameter circumference of the ring to be
positioned on the right side of the ring gap. The
lower compression ring needs to be installed
2. Indicates front of engine.
with the undercut side downward.
The upper and lower compression ring gaps are
not controlled for installation.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-54

 Group 00(L-Ford), Engine

• Upper oil control segment ring gap location. LXX. PISTON RING END GAP
• Oil control spacer gap location.
• Lower oil control segment ring gap location.

LIX. PISTON INSPECTION

NOTE
Use care when fitting piston rings to avoid pos-
sible damage to the piston ring or the cylinder
bore.
Piston rings should not be transferred from one
piston to another.
NOTE
Do not use a caustic cleaning solution or a wire The cylinder bore must be within specification
brush to clean the pistons or damage can occur. for taper and out-of-round.

1. Clean and inspect the (1) ring lands, (2) pin bosses, 1. Use a piston without rings to push a piston ring in a
(3) skirts and the (4) tops of the pistons. If wear cylinder to the bottom of ring travel.
marks, scores or glazing is found on the piston skirt,
check for a bent or twisted connecting rod.

2. Using the Feeler Gauge Set measure, the top piston

ring end gap and the second piston ring end gap.
NOTE
Make sure the oil ring holes are clean.

2. Using a Piston Ring Groove Scraper, clean the piston

ring grooves.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-55

 Group 00(L-Ford), Engine

LXXI. PISTON SELECTION LXXIII. ENGINE, LOWER ASSEMBLY

NOTE NOTE
Refer to the appropriate Section 303-01 for the Do not loosen or remove the crankshaft pulley
specifications. bolt without first installing the special tools as
instructed in this procedure. The crankshaft
pulley and the crankshaft timing sprocket are
not keyed to the crankshaft. The crankshaft, the
crankshaft sprocket and the pulley are fitted
together by friction, using diamond washers
between the flange faces on each part. For that
reason, the crankshaft sprocket is also unfas-
tened if the pulley bolt is loosened. Before any
repair requiring loosening or removal of the
crankshaft pulley bolt, the crankshaft and cam-
shafts must be locked in place by the special ser-
The cylinder bore must be within the specifica-
vice tools, otherwise severe engine damage may
tions for taper and out-of-round before fitting a
occur.
piston.

1. Measure the cylinder bore in 2 directions. NOTE

During engine repair procedures, cleanliness is
2. Select a piston size based on the cylinder bore. extremely important. All parts must be thor-
oughly cleaned and any foreign material,
including any material created while cleaning
LXXII. PISTON DIAMETER gasket surfaces, that enters the oil passages,
coolant passages or the oil pan, can cause engine
NOTE failure.
Refer to the appropriate Section 303-01 for the NOTE
specification.
Assembly of the engine requires various inspec-
Measure the piston diameter 90 degrees from tions/measurements of the engine components
the piston pin and 41 mm (1.61 in) down from (engine block, crankshaft, connecting rods, pis-
the top of the piston at the point indicated. tons and piston rings). These inspections/mea-
surements will aid in determining if the engine
components will require replacement.

NOTE
For additional information, refer to the
exploded views in Description and Operation in
this section.

For precision fit, new pistons are divided into

three categories within each size range based on
their relative position within the range. A paint
spot or specific size grade on a new piston indi-
cates the position within the size range.

1. Choose the piston with the correct paint color or spe-

cific size grade.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-56

 [GK>\, 

XV 3. Torque:
If the oil squirters are being reused, they must Stage 1: 5 Nm
be installed in the same location as marked dur- Stage 2: 25 Nm
ing disassembly. Stage 3: Tighten an additional 90°
XV
The front bulkhead does not have an oil
squirter.

1. Measure each of the crankshaft main bearing journal

diameters in at least directions and record the small-
est diameter for each journal.

4. Measure each crankshaft block main bearing bore

diameter.
5. Using the chart, select the crankshaft main bearings.

2. Position the main bearing beam in the engine block

with the main bearing beam mounted flush with the
rear face of the engine block and install the original
main bearing beam bolts finger tight.

/ @ &  >J[GK>\K*KIh

 [GK>\, 

BLOCK CODE
51.018 .019 .020 .021 .022 .023 .024 .025 .026 .027 .028 .029 .030 .031 .032 .033 .034 .035 .036 .037 .038 .039 .040
51.970
.979 UP
PE
.980 LO R B
W LU
U ER E
.981 LO PPE BL GR
W RB AC EE
.982 UP E R LA K N7
LO PE BL C 6
.983 W R AC K 6
ER B K
UP L
YE C A 6
.984 LO PE LL K
W RY OW 6
CRANKSHAFT CODE

.985 ER E
YE LLO 5
.986 UP LLO W 5
L PE W
.987 UP OW R 5
PE ER YE
R LL
.988 BR B RO OW
OW W
.989 N N 5
UP 4/ 4
.990 PE L O
LO R W
W BR ER
.991 ER O BR
UP RE WN OW
.992 LO PE D 4
3 N
W RR 4
.993 U
E R ED
LO PPE RE 3
.994 W R D
3
ER RE
.995 U BL D 3
LO PPE UE
.996 W RB 2
ER L
.997 BL UE
U U 2
LO PP E
.998 2
W ER
E R B
.999 L UPP GR LUE
O E EE 2
52.000 WERR GR N
1
GR EE
.001 EE N 1
N
.002 1

7. Torque:
Stage 1: 10 Nm
Stage 2: 29 Nm
Stage 3: Tighten an additional 90°

XV 8. Measure the connecting rod large end bore in 2 direc-

tions. Record the smallest measurement for each con-
The rod cap installation must keep the same ori-
necting rod. Remove the bolts and the connecting rod
entation as marked during disassembly or
cap. Discard the connecting rod cap bolts.
engine damage may occur.

6. Using the original connecting rod cap bolts, install

the 4 connecting caps and the 8 bolts.

/ @ &  >J[GK>\K*KI*

 [GK>\, 

10. Using the chart, select the correct connecting rod

bearings for each crankshaft connecting rod journal.

9. Measure each of the crankshaft connecting rod bear-

ing journal diameters in at least 2 directions. Record
the smallest measurement for each connecting rod
journal.

CONNECTING ROD
.023 .024 .025 .026 .027 .028 .029 .030 .031 .032 .033 .034 .035 .036 .037 .038 .039 .040 .041 .042 .043 .044 .045 .046 .047
16.976
.979
.980 RED/3
.981
.982
.983
BLUE/2
CRANKSHAFT CODE

.984
.985 RED/3
.986
.987
.988
.989 BLUE/2
.990
.991
.992
.993
.994 GREEN/1
.995 BLUE/2
.996
.997
.998
.999 GREEN/1
47.000
.001
.002

11. Remove the 10 bolts in the sequence shown and the

main bearing beam.

/ @ &  >J[GK>\K*KI;

 Group 00(L-Ford), Engine

NOTE 12. Apply a light coat of clean oil to all surfaces the
Before assembling the cylinder block, all sealing come in contact with other moving parts.
surfaces must be free of chips, dirt, paint and
foreign material. Also, make sure the coolant
and oil passages are clear.
If reusing the crankshaft main bearings, install
them in their original positions and orientation
as noted during disassembly.
The center bulkhead is the thrust bearing.
Apply clean oil to all surfaces that contact mov-
ing parts.

13. Mounted flush.

If reusing the crankshaft main bearings, install NOTE

them in their original positions and orientation Lubricate the main bearing beam bolts threads
as noted during disassembly. and under the bolt heads with clean engine oil.
Apply clean oil to lubricate the journals on the Position the crankshaft to the rear of the cylin-
crankshaft with clean engine oil. der block, then position the crankshaft to the
front of the cylinder block before tightening the
main bearing beam bolts.

14. Install and tighten the 10 new main bearing beam

bolts.

15. Torque bolts as follows:

Stage 1: 5 Nm
Stage 2: 25 Nm
Stage 3: Tighten an additional 90°

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-60

 Group 00(L-Ford), Engine

16. Position the crankshaft to the rear of the cylinder positioned on the right side of the ring gap. The
block. lower compression ring needs to be installed
with the undercut side downward.
17. Zero the Dial Indicator Gauge with Holding Fixture.
The upper and lower compression ring end gaps
18. Use Special Service Tool: 100-002.
are not controlled for installation:
19. Move the crankshaft to the front of the cylinder
block. Note and record the crankshaft end play. • Upper oil control segment ring gap location.
20. Acceptable crankshaft end play is 0.22-0.45 mm • Oil control spacer gap location.
(0.008-0.018 in). • Lower oil control segment ring end gap.
21. If the crankshaft end play exceeds the specified
range, install new parts as necessary.

NOTE
If reusing the connecting rod bearings, install
them in their original positions and orientation
as noted during disassembly.

NOTE
Be sure not to scratch the cylinder wall or
crankshaft journal with the connecting rod.
22. Apply the specified lubricant to the specified compo- Push the piston down until the connecting rod
nent. bearing seats on the crankshaft journal.
Make sure the piston arrow on top is facing
toward the front of the engine. Apply the speci-
fied lubricant to the specified component.

23. Torque bolts as follows:

Stage 1: 10 Nm
NOTE Stage 2: 29 Nm
Stage 3: Tighten an additional 90°
The piston compression upper and lower rings
should be installed with the paint mark on the
outside diameter circumference of the ring to be

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-61

 Group 00(L-Ford), Engine

NOTE 26. Install the adjustment shims in their original posi-

The rod cap installation must keep the same ori- tions on the seat faces of the balancer unit. With the
entation as marked during disassembly or balancer unit shaft marks in the TDC position, slowly
engine damage may occur. install the balancer unit to the cylinder block to avoid
interference between the crankshaft drive gear and
Install connecting rod caps and bolts on the con- the balancer unit driven gear.
necting rods for cylinders 1 and 4 first and
tighten. Then rotate crankshaft 180 degrees and
install connecting rod caps and bolts on con-
necting rods for cylinders 2 and 3 and tighten.
After installation of each connecting rod cap,
rotate the crankshaft to verify smooth opera-
tion.

27. Torque bolts as follows:

Stage 1: 25 Nm
Stage 2: 52 Nm

24. Install Special Service Tool 303-507.

25. Rotate the crankshaft slowly clockwise until the
crankshaft balance weight is up against the Crank-
shaft TDC Timing Peg. The engine is now at TDC.

NOTE
28. Remove Special Service Tool: 303-507.
Due to the precision interior construction of the
balancer unit, it should not be disassembled. 29. Rotate the crankshaft to confirm that there are no
meshing problems between the balancer unit gear
The original adjustment shims must be installed
and the crankshaft gear.
in their original positions.
30. Install Special Service Tool 303-507.
Confirm by visual inspection that there is no
damage to the balancer unit gear and verify 31. Rotate the crankshaft slowly clockwise until the
that the shaft turns smoothly. If there is any crankshaft balance weight is up against the Crank-
damage or malfunction, replace the balancer shaft TDC Timing Peg.
unit. 32. Remove Special Service Tool 303-507.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-62

 Group 00(L-Ford), Engine

33. Position as shown. Measure the gear backlash. Use

Special Service Tool: 100-002.
34. Position the Dial Indicator Gauge with Holding Fix-
ture (1) on the Allen wrench 80 mm (3.149 in) above
the driven gear shaft center (2) on the balancer unit.
35. Rotate the crankshaft clockwise and measure the
backlash at all of the following 6 positions: 10
degrees, 30 degrees, 100 degrees, 190 degrees, 210
degrees and 280 degrees.
36. Backlash specifications are 0.005 to 0.101 mm
(0.00019 to 0.0039 in).
37. If the backlash exceeds the specified range, carry out
the Balance Shaft Backlash procedure.
Refer to: LII BALANCE SHAFT BACKLASH
38. Install Special Service Tool: 303-507.
39. Rotate the crankshaft slowly clockwise until the
crankshaft balance weight is up against the TDC
Timing Peg. The engine is now at TDC and must
remain at the TDC position until the timing drive
components and crankshaft pulley are installed.

NOTE
Measure the backlash and verify that it is 40. Clean the oil pump and cylinder block mating sur-
within specified range all of the following 6 posi- faces using Motorcraft Metal Surface Prep / ZC-31-
tions: 10 degrees, 30 degrees, 100 degrees, 190 A.
degrees, 210 degrees and 280 degrees. It will be
41. Replace Oil Pump. Refer to L OIL PUMP
necessary to reset the measuring equipment
between measurements. 42. Replace Rear Seal of the Crankshaft.
Refer to LXIV CRANKSHAFT, REAR SEAL.
The measurement must be taken with the Dial
Indicator Gauge with Holding Fixture, a 5-mm NOTE
Allen wrench and worm clamp set up as shown. Do not use metal scrapers, wire brushes, power
Mark the Allen wrench with a file 80 mm (3.149 abrasive discs or other abrasive means to clean
in) above the driven gear shaft center. Make the sealing surfaces. These tools cause scratches
sure the worm clamp and Allen wrench are not and gouges, which make leak paths. Use a plas-
touching the balance shaft housing. tic scraping tool to remove traces of sealant.
For an accurate measurement while measuring
43. Replace Oil Pan. Refer to XLVIII. OIL PAN
the gear backlash, insert a screwdriver as
shown into the crankshaft No. 1 crankweight 44. For the installation and alignment of the Timing
area and set both the rotation and the thrust Chain, Timing Chain Cover, Camshafts and relation
direction with the screwdriver, using a prying components, refer to XLIII CAMSHAFT AND/OR
action as shown. TAPPET REPLACEMENT.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-63

 [GK>\, 

G__%? W9X^<9>,W9W9G G__? %UV?W,VVG9X

W/V?9G W/V?9G
1. Remove flywheel.
Refer to XXXVI. FLYWHEEL/FLEX PLATE
2. Remove Oil Pan. Refer to Refer to XLVIII. OIL PAN.
3. Remove bolts securing the rear crankshaft seal.

1. Remove bolts.

%X9GG9%VX
1. Replace seal.
2. Torque bolts to 10 Nm in the order shown below.

2. Inspect seal for damage and replace if necessary.

%X9GG9%VX
1. Lightly coat seal with coolant.
2. Replace and secure with bolts. Torque to 10Nm.

3. Replace Oil Pan. Refer to Refer to XLVIII. OIL PAN.

4. Replace flywheel.
Refer to XXXVI. FLYWHEEL/FLEX PLATE

/ @ &  >J[GK>\K*K

 Group 00(L-Ford), Engine

LXVI THERMOSTAT LXXVI. WATER PUMP

REMOVAL REMOVAL
1. Remove hoses. 1. Remove the pulley and belt.
Refer to XXXIII Pulleys/Belt-Alternator.
2. Remove bolts securing thermostat housing.
2. Remove three bolts securing the water pump and
remove the pump.

NOTE
Clean the coolant pump mating surfaces.
Install a new O-ring seal.
3. Apply a light coat of coolant to the sealing surface
and torque as follows:
3. Inspect the thermostat and gasket. Replace thermo- Stage 1 Torque: 10 Nm
stat and/or gasket if necessary. Stage 2 Torque: 20 Nm

INSTALLATION

1. Torque bolts to 10 Nm
2. Install hoses.

4. Replace the pulley and belt.

Refer to XXXIII Pulleys/Belt-Alternator.

SM 1044 Servicing the Fuel System • 00(L-Ford)-8-65

 [GK>\, 

G__?%% ]G%XUW"GV^VW XV

=G W=G9/X When installed, the flanged edge must be below
the chamfered edge of the bore to effectively
All Core Plugs seal the bore. Coat the cup-type core plug with
Threadlock and Sealer / TA-25and bore lightly
with sealant and install the core plug using a
freeze plug installer. Remove the excess sealant
after installation.

Expansion-Type

XV
Do not contact the crown when installing an
expansion-type core plug. This could expand
the plug before seating and result in leakage.

XV 3. Coat the expansion-type core plug and bore lightly

Cylinder block core plug shown, cylinder head with Threadlock and Sealer / TA-25 and install the
core plug is similar. core plug using a freeze plug installer.
Remove the excess sealant after installation.
1. Using the Slide Hammer and a commercially avail-
able body dent puller attachment or commercially
available freeze plug puller, remove the core plug.
Use Special Service Tool 100-001.

XV
Oversize plugs are identified by the OS stamped
in the flat located on the cup side of the plug.

2. Inspect the core plug bore for any damage that would
interfere with the correct sealing of the plug. If the
core plug bore is damaged, bore for the next oversize
plug.

G__?%%% W9X^9 ?X%G9K

Cup-Type %VX]/%X=%VX$U%9K
XV% W G V> %XVWW
V=W9%VX
A plugged positive crankcase ventilation (PCV) orifice or
hose may cause the following conditions:
• Rough or unstable engine speed
• Stalling or low idle speed
• Oil leaks
• Oil in the air cleaner
• Sludge in the engine
XV
Use care during this procedure so as not to dis- A leaking PCV orifice or hose may cause the following
turb or distort the cup sealing surface. problems:
• Rough or unstable engine speed.

/ @ &  >J[GK>\K*K

 [GK>\, 

• Stalling %/=VW9X
• High idle speed Use only 50/50 mix of Boron-free antifreeze
with distilled water. Do not add plain water.
Functional check: Replace coolant per the recommended schedule.
Any blow-by in excess of the system capacity, from a
%/=VW9X
badly worn engine, sustained heavy load, etc., is
exhausted into the air cleaner and is drawn back into the Only replace coolant with same color originally
engine. included or shipped with the engine. Do not mix
coolant.
Proper operation of the crankcase ventilation system
depends on a sealed engine. If irregular oil flow or dilu- %/=VW9X
tion is noted and the crankcase ventilation system is func- The manufacturers of the engine and fuel sys-
tioning properly, check the engine for another possible tem do not recommend the use of “stop leak”
cause. Correct any of these problems first. additives to repair leaks in the cooling system. If
If an engine is idling rough, inspect for a clogged PCV leaks are present the radiator should be
orifice, a dirty vent filter, air cleaner element, or plugged removed and repaired or replaced.
hose. Replace any faulty items found. Use the following
procedure:
=WVU W
• Remove the PCV hose (positive side) from the
rocker arm cover. 1. Disconnect Negative battery cable.
• Operate the engine at idle. 2. Locate the drain plug on the right side of the engine.
• Place your thumb over the end of the hose in order Refer to the illustration below.
to check for vacuum. If there is no vacuum at the
hose end, inspect for plugged hoses or a blockage
at the manifold vacuum port.

If a problem is found:
• Turn the engine OFF.
• Inspect the PCV orifice in the valve cover for
debris or blockage.
• Clean as necessary. If PCV is suspected, clean or
replace.

Side of the engine showing the

G__%_ UW9%X%X<VVG9X location of engine block drain plug.

! 9 %VX 3. Set up a catch basin and remove the drain plug.

The coolant may be hot. Use caution and avoid 4. Drain the coolant. If necessary, lift any flexible cool-
contact when working with the coolant. ant hoses to drain trapped coolant into the block.
5. Once the coolant has been drained, apply Loctite ®
%/=VW9X 567 to the drain plug, reinstall and torque until tight.
The following instructions pertain to draining Dispose of the old coolant in a proper manner.
the engine block only. If the coolant is to be
changed, the radiator should also be drained. 6. Refill coolant using a 50/50 mix of Boron-free anti-
Refer to the OEM instructions for draining the freeze with distilled water.
radiator. 7. Reconnect negative battery cable.
8. Start engine and verify engine is in closed loop and
no MIL light is present.

/ @ &  >J[GK>\K*Kh

 [GK>\, 

9. Run engine until it reaches normal operating temper-

ature and check for coolant leaks.
X%X=%>%9%VX
GENERAL
10. Turn off engine and allow to cool. Top off coolant in
Displacement: 2.5L (152 in3)
the radiator and/or coolant recovery tank as neces-
Cylinders: 4
sary.
Fuel Delivery: Sequential Multiport Fuel Injection
Engine block: Aluminum
Cylinder head: Aluminum, with Valve Seat Inserts
G___ >G]'<G9U9=W7 Bore/Stroke: 3.50/3.93” (89.0/100.0mm)
<V %X Firing Order: 1-3-4-2
Rotation: Clockwise (as viewed from front/fan side)
W/V?9G Compression Ratio: 9.7:1
Weight (Including Flex Plate): 310 lbs. (140.8 Kg)
Idle RPM: ~750 RPMs
Max RPM: 2500 (Governed)
Max Torque: 142 ft.lbs. (192 Nm) @1800 RPMs
Peak Power: 64 HP (48 kW)
Ford Engine Part Number: DG-338-AA (engine
complete) DS7E-6006-BA (Long Block)

IGNITION SYSTEM SPECIFICATIONS

Coil on plug
Spark Plug Gap: 0.031 inches (0.8 mm).
Base Timing: LPG: 0° BTDC at idle
1. Remove the Flexplate.
Refer to XXXVI. FLYWHEEL/FLEX PLATE. VALVE SPECIFICATIONS
2. Remove the four screws securing the Flexplate Valves/Cylinder: 4
Adapter to the Flexplate. Valve Lifter/Lash Adjuster: Direct Acting Mechanical
Buckets or Tappets.
3. To remove the Flexplate Housing, remove the 7 Tappet to valve clearance, Intake: 0.003-0.012 in (0.075-
screws securing the Housing to the engine. 0.310 mm)
Tappet to valve clearance, Exhaust: 0.005-0.016 in
%X9GG9%VX (0.125-0.42 mm)
Lash Face Angle Intake and Exhaust: 45° Seat Angle
1. To install the Flexplate Housing, align the housing Intake and Exhaust: 46°
and place it on the back of the engine. Insert and fin- Seat Runout Intake and Exhaust: 0.002” (0.0508 mm)
ger tighten screws, then torque to 40.5 +/- 4 ft.lbs (55 Maximum Seat Width - Intake: 0.050 -0.070” (1.270-
+/-5 Nm) in a crisscross pattern. 1.778 mm), Exhaust: 0.060-0.080” (1.524-2.032 mm)
2. To install the Flexplate Adapter, align the four holes Maximum Valve Spring Free Length: 2.06” (52.324 mm);
with the Flexplate, insert screws and finger tighten, Pressure Closed 100-110 Ibis @ 1.61” (444-490
then torque to 30 +/-1.5 ft.lbs (40 +/- 2 Nm) in a N @ 40.89 mm); Open 208-222 Ibis @ 1.22” (925-
crisscross pattern. 987 N @ 30.99 mm); Installed Height 1.65” (41.91
mm)
3. Install the Flexplate. Valve Lift - Intake and Exhaust: 0.443” (11.2522 mm)
Refer to XXXVI. FLYWHEEL/FLEX PLATE.. Valve Spring Damper: Not Used

AIR INTAKE SYSTEM

Minimum Intake Air Flow Rate: 4.11 m3/min (145 CFM)
Maximum Allowable w/Clean Element: 10” w.c. (254
mm w.c.)
Intake Restriction: w/Dirty Element: 20” w.c. (508 mm)

/ @ &  >J[GK>\K*K*

 [GK>\, 

EXHAUST Ring groove width - oil: 2.51-2.53 mm (0.0988-0.0996 in)

Back Pressure: 2.5 PSI (18.7 kPa); Minimum Allowable Piston skirt coating thickness: 0.008-0.016 mm (0.0003-
Exhaust Pipe Size: 1{” (38 mm) 0.0006 in)
Exhaust Manifold: Cast iron w/heat shield.
Piston Pin
CRANKCASE VENTILATION Item Specification
Foul Air System w/PCV, closed type Diameter: 19.995-20.0 mm (0.8265-0.8267 in)
Length: 54.7-55.0 mm (2.1535-2.1653 in)
COOLING SYSTEM Pin-to-rod clearance Floating pin
Thermostat Temperature: 180°F (82°C)
Max Coolant Temperature @ Top Tank of Radiator: Cylinder Head
210°F (98°C) @ 2600 RPM Item Specification
Maximum Restriction at Pump Inlet: 1.5 PSI (10 kPa) Cylinder head flatness: 0.08 mm (0.0031 in) maximum
Cooling Water Capacity (block only): 4.0 qts (3.8 L) overall, a maximum of 0.05 mm (0.0019 in) within
150 mm (5.9 in)
LUBRICATION SYSTEM Valve guide diameter: 5.509-5.539 mm (0.216-0.218 in)
Oil Pressure (Min Hot): 2.5-3.5 psi (17.2-31.0 kPa) Valve seat width - intake/exhaust: 0.99-1.84 mm (0.038-
Oil Temperature: Upper Limit: 266°F (130°C) 0.072 in)
Crankcase Capacity: Standard Pan: 5.4 qts (5.1 L) w/Oil Valve seat angle: 45 degrees
Filter: 5.7 qts (5.4 L) Valve seat runout: 0.075 mm (0.0029 in)
Oil Filter Location: Right rear on engine Valve tappet bore diameter: 31.00-31.03 mm (1.220-1.221
in)
Cam bore diameter: 25.015-25.040 mm (0.984-.0985 in)
ADDITIONAL SPECIFICATIONS
AND TOLERANCES Valve
Item Specification
Valve head diameter - intake: 34.85-35.15 mm (1.372-
Cylinder Block 1.383 in)
Item Specification Valve head diameter - exhaust: 29.85-30.15 mm (1.175-
Cylinder bore diameter: 89.0-89.03 mm (3.503-3.505 in) 1.187 in)
Cylinder bore maximum out-of-round: 0.008 mm (0.0003
in) Valve stem diameter - intake: 5.470-5.485 mm (0.2153-
Main bearing bore diameter: 57.018-57.040 mm (2.244- 0.2159 in)
2.245 in) Valve stem diameter - exhaust: 5.465-5.480 mm (0.2151-
Head gasket surface flatness: 0.1 mm/general 0.05 mm/ 0.2157 in)
200 x 200 (0.004 in/ general) (0.0019 in/7.87 x 7.87) Valve stem-to-guide clearance - intake: 0.0027 mm
(0.00010 in)
Piston Valve stem-to-guide clearance - exhaust: 0.0029 mm
Item Specification (0.00011in)
Piston Diameter (1): 88.965-88.975 mm (3.5025-3.5029
Valve face runout: 0.05 mm (0.0019 in)
in)
Valve face angle: 45 degrees
Piston Diameter (2): 88.9725-88.9875 mm (3.5028-
3.5034 in)
Piston Diameter (3): 88.985-88.995 mm (3.5033-3.5037
in) Valve Spring - Compression Pressure
Piston-to-bore clearance: 0.0225-0.0475 mm (0.0009- Item Specification
0.0019 in) Intake and exhaust (installed): 18 kg (39.683 lb)
Ring groove width - top: 1.23-1.25 mm (0.0484-0.0492 Intake (valve open): 9.2 mm (0.362 in of lift) 46 kg
in) (101.41 lb)
Ring groove width - 2nd: 1.22-1.24 mm (0.0480-0.0488 Exhaust (valve open): 9.2 mm (0.362 in of lift) 46 kg
in) (101.41 lb)

/ @ &  >J[GK>\K*K;

 [GK>\, 

Free length: 47.91 mm (1.886 in) VW` =%>%9%VX

Assembled height: 37.9 mm (1.492 in) CMP (camshaft position) sensor bolt: 7 Nm - 62 lb-in
Coil-on-plug stud bolts: 10 Nm - 89 lb-in
Crankshaft Coolant outlet bolts: 10 Nm - 89 lb-in
Item Specification Coolant pump bolts: 10 Nm - 89 lb-in
Main bearing journal diameter: 51.978-52.002 mm
Coolant pump pulley bolts: 20 Nm - 177 lb-in
(2.046-2.047 in)
Crankcase vent oil separator bolts: 10 Nm - 89 lb-in
Production repair: 51.730-51.750 mm (2.036-2.037 in)
Main bearing clearance: 0.016-0.047mm (0.0006-0.0015 Cylinder block pipe plug: 56 Nm - 41 lb-ft
in) CHT (cylinder head temp.) sensor: 12 Nm - 106 lb-in
Connecting rod journal diameter: 51.978-52.002mm Engine mount bolts: 90 Nm - 66 lb-ft
(2.046-2.047 in) Engine mount nuts: 90 Nm - 66 lb-ft
Production repair: 51.730-51.750mm (2.036-2.037 in) Exhaust manifold studs: 15 Nm - 11 lb-ft
End play: 0.220-0.450 mm (0.008-0.018 in) Engine Oil Pressure Switch: 15 Nm - 133 lb-in
Engine lift eye bolts: 47 Nm - 35 lb-ft
Rings Engine plug bolt: 20 Nm - 177 lb-in
Item Specification Engine Hanger Bolts: 25 Nm - 18 lb-ft
Width - top: 1.17-1.19 mm (0.0460-0.0469 in) Exhaust manifold heat shield bolts: 90 Nm - 66 lb-ft
Width - 2nd: 1.17-1.19 mm (0.0460-0.0469 in) Exhaust pipe flange nuts: 48 Nm - 35 lb-in
Width - oil: 2.38-2.45 mm (0.093-0.096 in) Engine mount studs: 20 Nm- 177 lb-in
Ring gap (in bore) - top: 0.16-0.26 mm (0.006-0.0102 in) Exhaust manifold nuts: 55 Nm - 41 lb-ft
Ring gap (in bore) - 2nd: 0.31-0.46 mm (0.012-0.018 in) Oil pan drain plug: 28 Nm - 21 lb-ft
Ring gap (in bore) - oil: 0.15-0.40 mm (0.0059-0.0157 in) Oil pump drive chain tensioner bolt: 10 Nm - 89 lb-in
Oil pump drive chain tensioner shoulder bolt: 10 Nm - 89
lb-in
Camshaft
Oil Pump screen and pickup bolts: 10 Nm - 89 lb-in
Item Specification
Oil pump sprocket bolt: 25 Nm - 18 lb-ft
Lobe lift - intake: 9.44 mm (0.371 in)
Oil squirter: 4 Nm - 35 lb-in
Lobe lift - exhaust: 8.18 mm (0.322 in)
Spark plug: 12 Nm - 106 lb-in
Runout (1)*: 0.03 mm (0.001 in)
Thermostat housing bolts: 10 Nm - 89 lb-in
Thrust clearance: 0.09-0.24 mm (0.003-0.009 in)
Timing chain guide bolts: 10 Nm - 89 lb-in
Journal diameter: 24.96-24.98 mm (0.982-0.983 in)
Journal-to-bore clearance: 0.035-0.080 mm (0.001-0.003 Timing chain tensioner bolts: 10 Nm - 89 lb-in
in)
* No. 3 Journal - Supported by No. 1 and No. 5 journals.
Connecting Rod
Item Specification
Bearing clearance: 0.027-0.052 mm (0.001-0.002 in)
Bearing thickness: 1.496-1.520 mm (0.058-0.059 in)
Crank bore diameter: 55.025-55.045 mm (2.166-2.167 in)
Pin bore diameter: 20.010-20.021 mm (0.7878-0.788 in)
Length (center to center): 151.8 mm (5.976 in)
Side clearance: 1.95-3.05 mm (0.076-0.120 in)
Axial clearance: 0.14-0.36 mm (0.005-0.014 in)

/ @ &  >J[GK>\K*Kh