Assembly

NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.

Special Tools:

1. Install the upper crankshaft main bearings in the cylinder block.
- The third bearing from the front of the engine is the thrust bearing.

2. Install the lower crankshaft main bearings in the bearing caps.
- The third bearing from the front of the engine is the thrust bearing.

3. Note: Make sure the Woodruff key is installed in the end of the crankshaft.

Install the crankshaft.
- Lubricate the main bearings and crankshaft journals with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

4. Note: If not secured within four minutes, sealant must be removed and the sealing area cleaned with solvent. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Clean the mating surfaces on the rear main bearing cap and the cylinder block.
- Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A.
- Apply a small amount of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 in the location shown in the illustration.

5. Install the main bearing caps.
- Arrows on the bearing caps indicate installation direction and location.
- Tighten the two bolts and six stud bolts in two stages.
- Stage 1: 50 Nm (37 ft. lbs.)
- Stage 2: 115 - 125 degrees

6. Install the camshaft.
- Lubricate the camshaft bearings, lobes and journals with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

7. Install the engine dynamic balance shaft.
- Lubricate the balance shaft bearings with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

8. Install the timing chain vibration damper.

9. Install the balance shaft drive gear.
- Timing marks on the balance shaft drive gear and driven gear must align.

10. Install the crankshaft sprocket, camshaft sprocket and timing chain as an assembly.
- Timing marks on gears and keyways on shafts must align.

11. Install the synchronizer drive gear.

12. Install the bearings in the piston connecting rod and rod cap.
- Lubricate the connecting rod bearings and crankshaft journals with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
- Lubricate the cylinder walls with clean engine oil and install the pistons. The arrow on the top of the piston must face the front of the engine and the notches in the bearing shells must align.

13. Note: All timing marks must be aligned with the number one piston at Top Dead Center (TDC).

Turn the crankshaft to position the number one piston at Top Dead Center (TDC). Crankshaft must not be turned until camshaft synchronizer is installed.

14. Position a new engine front cover gasket and install the engine front cover.
- Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten bolts 1-11 and 13 to 25 Nm (16 ft. lbs.).
- Stage 2: Tighten bolt 12 to 25 Nm (18 ft. lbs.).
- Stage 3: Tighten bolts 1-11 and 13 an additional 90 degrees.

15. Install the oil baffle assembly.

16. Install the oil pump screen cover and tube.
- Use a new gasket.

17. Note: If not secured within four minutes, sealant must be removed and the sealing area cleaned with solvent. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Clean mating surfaces on the oil pan and the cylinder head.
- Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A.
- Apply a bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 as shown in the illustration.

18. Install the rear seal and oil pan.
- Tighten the bolts in two stages in the sequence shown.
- Stage 1: 4 - 5 Nm (36 - 44 inch lbs.)
- Stage 2: 9 - 12 Nm (80 - 106 inch lbs.)
19. Install the camshaft synchronizer.

20. Install the water bypass hose.
- Use a new O-ring seal.

21. Install the valve tappets and tappet guides.
- Lubricate the tappet bore and tappet roller with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

22. Install the cylinder heads.
- Use new gaskets and bolts.
- Tighten the bolts in three stages in the sequence shown:
- Stage 1: 20 Nm (14 ft. lbs.)
- Stage 2: 40 Nm (29 ft. lbs.)
- Stage 3: 50 Nm (36 ft. lbs.)

23. CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened and the final tightening completed prior to working on the next bolt in the sequence.

In the sequence shown, loosen the bolt three turns, then tighten the (A) short bolt or (B) long bolt to the specification indicated, and then further tighten the bolt to the (C) degrees indicated.

24. Note: Lubricate the ends of the push rods and rocker arm seats with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the rocker arms, rocker arm seats and push rods in the following positions:
- Number 1 - intake and exhaust
- Number 2 - exhaust
- Number 3 - intake
- Number 4 - exhaust
- Number 6 - intake