Steps 1 - 51
NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.
Special Tools:
1. WARNING: Eye protection is required to be worn during use of compressed air. Failure to follow these instructions could result in possible personal injury.
Clean and dry the cylinder block.
- Clean gasket material, dirt and debris from the cylinder block.
- Wash the cylinder block with a suitable soap and water solution.
- Dry the cylinder block completely using compressed air.
2. If required, install the new pipe plugs and alignment dowels.
3. Install the crankshaft key.
4. If required, on manual transaxles install a new crankshaft pilot bearing.
5. Install the upper crankshaft main bearings, the upper crankshaft thrust main bearing and the lower crankshaft main bearings.
6. Position the crankshaft.
7. Determine crankshaft main bearing clearance.
8. Apply a light coat of Super Premium 5W-30 SAE Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to the crankshaft bearings and journals.
9. CAUTION: Make sure the main bearing caps are installed in their original position or engine damage may occur.
Install the main bearing caps.
10. Loosely install the bolts.
11. Tighten the bolts in the sequence shown.
12. Note: Do not remove the wedge until the crankshaft main bearing thrust cap bolts are tightened.
Wedge the crankshaft forward to fully seat the crankshaft thrust main bearings, while prying the crankshaft main bearing thrust cap to the rear.
13. Tighten the bolts.
14. Rotate the crankshaft and inspect for excessive drag or binding.
15. Inspect the crankshaft end play.
16. Note: The clearance between the lower cylinder block sealing surfaces on the crankshaft rear oil seal retainer and the crankshaft cannot exceed 0.2 - 0.8 mm (0.008 - 0.031 inch).
Install the crankshaft rear oil seal retainer.
- Install the new crankshaft rear oil seal retainer gasket.
- Install the crankshaft rear oil seal retainer.
- Install the bolts.
17. Note: Lubricate the crankcase flange and the crankshaft rear oil seal bore with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installing the crankshaft front seal or damage to the crankshaft front seal may occur.
If required, replace the crankshaft front seal.
18. CAUTION: PIP mark on pistons and squirt groove on connecting rods must be located on the intake side of the engine or possible engine damage may occur.
CAUTION: Use care when installing piston and connecting rod assemblies. Do not scratch the cylinder walls or the crankshaft journals or engine damage may occur.
CAUTION: The arrow on the piston must point toward the front of the engine or engine damage may occur.
Note: Lubricate the cylinder block, piston rings and connecting rod (6200) prior to installation with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford Specification WSS-M2C153-G.
Install four piston and connecting rod assemblies using the Connecting Rod Guides and the Piston Ring Compressor.
19. Note: Turn the crankshaft each time to install the connecting rod caps.
Fit the connecting rod bearing.
- Install the four upper and the four lower connecting rod bearings.
- Inspect the connecting rod bearing to the crankshaft clearance.
20. CAUTION: Connecting rods and connecting rod caps must be properly oriented, the interlocking tangs on the same side of the connecting rod or possible engine damage may occur.
Note: Lubricate the connecting rod bearings and the crankshaft journals prior to installation with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
Note: Rotate the crankshaft after installing each connecting rod cap and inspect for excess drag or binding.
Install the four connecting rod caps.
- Install the four connecting rod caps.
- Install the new bolts and tighten in two steps:
- Tighten to 35 Nm (26 ft. lbs.).
- Tighten an additional 90 degrees.
21. Inspect the connecting rod clearance.
22. Note: The clearance between the lower cylinder block sealing surfaces on the oil pump and the cylinder block cannot exceed 0.3 - 0.8 mm (0.012 - 0.031 inch).
- Install the new oil pump gasket (7A136).
- Install the oil pump.
23. CAUTION: The lower engine block must be installed and the bolts tightened to specification within four minutes of sealant application or possible leakage may occur.
Apply a 3 mm (0.1 inch) bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 sealer in four places where the oil seal retainers meet the cylinder block.
24. Install a gasket and the lower cylinder block. Tighten the bolts in two steps in the sequence shown.
Tighten the bolts to 7 - 13 Nm (62 - 115 inch lbs.).
Tighten the bolts to 20 - 24 Nm(15 - 17 ft. lbs.).
25. Install the oil pump cover and screen.
- Install new oil pump inlet tube gasket.
- Install the oil pump cover and screen.
26. Note: The oil pan must be installed and the .bolts tightened to specification within four minutes of sealant application.
Apply a 3 mm (0.1 inch) bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
27. Install the oil pan. Tighten the bolts in the sequence shown.
28. Install the crankshaft position sensor (CKP sensor) and bushing.
29. Turn the engine upright on stand.
30. Install the water pump housing.
31. Assemble the cylinder head.
32. CAUTION: The bolts are torque-to-yield and must be replaced or engine damage may occur.
Tighten the bolts in three steps in the sequence shown.
- Tighten the bolts to 15 - 25 Nm (12 - 18 ft. lbs.).
- Tighten the bolts to 35 - 45 Nm (26 - 33 ft. lbs.).
- Tighten the bolts an additional 105 degrees.
33. Loosely install the crankshaft pulley, then position the engine at top dead center cylinder No. 1.
34. Note: Lubricate the valve tappets prior to installation with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
Note: If valve tappets are being reused the valve tappet must be installed in its original position or engine damage may occur. Mark the valve tappet for proper location.
Install valve tappets.
35. Select and install valve clearance shims.
36. Install the oil control solenoid and bushing on the exhaust camshaft.
37. CAUTION: The engine must be at top dead center or engine performance may suffer.
Install the camshafts.
38. Install the camshaft front oil seals.
39. CAUTION: The cylinder head camshaft journal thrust cap must be installed first to properly position the camshaft in the cylinder head.
Note: Apply a bead of Gasket Maker F8AZ-1913508-AB or equivalent meeting Ford specification WSK-M2G348-A5 to the sealing surfaces of the front camshaft journal thrust cap prior to installation.
Note: Lubricate the camshaft bearing surfaces with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to assembly.
Install the camshaft journal thrust caps.
40. Install the camshaft journal cap bolts. Tighten the bolts in several two-step passes in the sequence shown.
41. Turn the oil control solenoid bushing one full turn and inspect for binding.
42. Install the timing belt cover backplate.
43. Position the single hole in the bushing at the 12 o'clock position.
44. Install the timing belt routing pulleys.
45. Install the timing belt guide and crankshaft sprocket.
46. Install the bolts. Tighten the bolts in the sequence shown.
47. Note: Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block.
Position the crankshaft just prior to top dead center.
48. Install the crankshaft TDC Timing Peg.
49. Rotate the crankshaft clockwise against the peg.
50. Note: Installation of the alignment tool into the exhaust camshaft may require the camshaft to be rotated clockwise.
Install the Camshaft Alignment Timing Tool on the back of the camshafts.
51. Install the intake timing sprocket and loosely install the bolt.