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ASSEMBLY: ENGINE (ENGINE - 3....

ASSEMBLY: ENGINE (ENGINE - 3.0L (2V)) Procedure SGML ID: N152844SECTION 303-01B: Engine - 3.0L (2V) 2000 Ranger Workshop ManualASSEMBLY Procedure revision date: 01/30/2004

Engine

Special Tool(s)

Piston Ring Compressor 303–D032 (D81L-6002-C)

Camshaft Bearing Service Set 303-017 (T65L-6250-A)

Crankshaft Damper/Seal Installer 303-175 (T82L-6316-A)

Synchronizer Alignment Gauge 303-589

Material

Item Specification

Gasket Maker F8AZ-19B508-AB or equivalent

WSK-M2G348-A5

Silicone Gasket and Sealant F7AZ-19554-EA or equivalent

WSE-M4G323-A4

Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent

WSS-M2C153-G

Pipe Sealant with Teflon® D8AZ-19554-A or equivalent

ESR-M18P7-A

1. Install the engine support insulators.

2. Install the oil pressure sender.

3. Install the upper crankshaft main bearings.

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4. NOTE: Lubricate the crankshaft journals and the crankshaft main bearings with super premium motor oil.

Install the crankshaft.

5. NOTE: Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with super premiummotor oil.

Install the crankshaft rear oil seal.

6. Apply two dots of gasket maker between the rear bearing cap and the cylinder block.

7. Install the lower crankshaft main bearings.

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8. Install the main bearing caps.

9. Wedge a large screwdriver at the location shown to hold the crankshaft forward until all the bolts aretightened.

10. Install the bolts.Tighten the bolts in pairs.For crankshaft and crankshaft bearing component tests, refer to Section 303-00.

11. If removed, install the camshaft bearings.Use the Camshaft Bearing Service Set.

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12. NOTE: Lubricate the camshaft and the camshaft bearings with super premium motor oil.

Install the camshaft.

13. Install the camshaft retainer.

14. Inspect the camshaft end play. For additional information, refer to Section 303-00.

15. Align timing marks.

16. Install the timing chain/belt, the camshaft sprocket and the crankshaft sprocket as an assembly.

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17. Install the bolt.

18. NOTE: Lubricate the connecting rod bearings with super premium motor oil.

Install the connecting rod bearings.

19. NOTE: Lubricate the piston and connecting rod assemblies with clean super premium motor oil.

Install the piston and connecting rod assemblies.Use a piston ring compressor.

20. Install the connecting rod caps and nuts.Tighten the nuts in pairs.

21. Install the oil pump.

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22. NOTE: Lubricate the valve tappets with super premium motor oil.

Install the valve tappets.

23. Install the valve tappet guide plates.

24. Install the valve tappet guide plate retainer.

25. Clean and inspect the cylinder heads. For additional information, refer to Section 303-00.

26. Install the head gaskets.

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27. Install the cylinder heads.

28. NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. Always install new bolts.

Install the bolts. Tighten the bolts in the sequence shown in five steps.1. Tighten the bolts to 50 Nm (59 lb-ft).2. Loosen the bolts one full turn.3. Tighten to 30 Nm (34-40 lb-ft).4. Tighten the bolts 90 degrees.5. Tighten the bolts an additional 90 degrees.

29. Install the oil bypass filter.

30. Install the oil level indicator tube.

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31. Install the EGR valve to exhaust manifold tube.

32. CAUTION: All timing marks must be aligned with the No. 1 cylinder set on top dead center(TDC) of the compression stroke or the synchronizer assembly will not be installed correctly.

NOTE: The crankshaft must not be turned until the camshaft synchronizer is installed.

Align the timing marks.

33. Install a new engine front cover gasket and the engine front cover.

34. Apply pipe sealant on the bolts to be installed in the locations shown.

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35. Install the bolts.Tighten the bolts in the sequence shown.

36. Install the crankshaft position (CKP) sensor.

37. Apply four beads of gasket maker as shown.

38. Position the oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with thegasket clips.

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39. NOTE: Make sure the fasteners are clean and dry prior to installation.

Tighten the oil pan bolts to 12 Nm (9 lb-ft) in the sequence shown.

40. CAUTION: After installation, do not loosen the synchronizer bolt and rotate the synchronizerassembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt afterthe alignment tool has been removed in order to align the CMP electrical connector for any reason.If the electrical connector is not in the correct position, the synchronizer assembly must beremoved, the alignment tool and the assembly reinstalled, if the engine has not been rotated fromTDC of the compression stroke on the No. 1 cylinder.

CAUTION: A Synchronizer Alignment Gauge must be used during the installation of thesynchronizer assembly. Failure to follow this procedure will result in the fuel system being out oftime with the engine, possibly causing engine damage.

Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in thecamshaft synchronizer housing.

41. NOTE: Always coat the synchronizer drive gear with clean engine oil prior to installation.

NOTE: During installation, the arrow on the Synchronizer Alignment Gauge will rotate clockwise as the gearsengage.

Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 38degrees from the centerline of the engine.

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42. Install the camshaft synchronizer retaining bolt.

43. Install the camshaft position (CMP) sensor.

44. Apply four beads of Silicone Gasket and Sealant.Use silicone gasket and sealant.

45. Install the intake manifold gaskets and end seals.Position the end seals.Position the intake manifold gaskets.

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46. Install the lower intake manifold.Tighten the bolts in the sequence shown.

47. Install the push rods and the rocker arms.Install the push rods.Install the rocker arms.Tighten the rocker arm bolts.

48. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.

49. If removed, install the valve cover gaskets.

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50. Install the valve covers.Tighten the bolts in the sequence shown.

51. Install the engine wiring harness.

52. Position the engine control sensor wiring and connect:the CMP sensor.the fuel injectors.the water temperature indicator sender unit.the engine control sensor wiring.the oil pressure sender.

53. Clean and inspect the upper intake manifold.

54. Install the intake manifold upper gasket.

55. Install the positive crankcase ventilation (PCV) valve.

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56. Install the upper intake manifold.Install the upper bolts.Tighten in the sequence shown.

57. Connect the EGR tube to the EGR valve.

58. Install the upper intake manifold support bracket.

59. Connect the engine control sensor wiring to:the idle air control (IAC) valve.the throttle position (TP) sensor.the EGR transducer.

60. Apply silicone gasket and sealant to the crankshaft damper keyway. Using the Crankshaft Damper/SealInstaller, install the crankshaft damper.

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61. Install the bolt.

62. Install the crankshaft vibration damper and the bolts.

63. Install the water pump pulley and the bolts.

64. Install the generator mounting bracket and the bolts.

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65. Install the nuts.

66. Connect the engine control sensor wiring to:the ignition coil.the radio ignition interference capacitor.the EGR solenoid.the vacuum line from the EGR solenoid.

67. Connect the vacuum line.

68. Connect the spark plug wires. For additional information, refer to Section 303-07B.

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This publication contains material that is reproduced and distributed under a license from Ford Motor Company. Nofurther reproduction or distribution of the Ford Motor Company material is allowed without the express writtenpermission of Ford Motor Company. Copyright 2007 - 2013 Service Repair Solutions, Inc.