Steps 1 - 50

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:

CAUTION: The moving components must be lubricated with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G before assembly.

CAUTION: The components with oil holes must be properly aligned with the oil feed holes.





1. If necessary, install the following:
1 the cylinder block dowels.
2 the oil gallery plugs.
3 the water jacket plugs.
2. If equipped, install the engine coolant heater.





3. Install the engine dynamic balance shaft bearings.





4. Install the camshaft bearings.





5. Install the following:
1 The engine dynamic balance shaft bearing cover.
2 The camshaft bearing cover.





6. CAUTION: Do not damage the camshaft lobes when installing the camshaft.

Install the camshaft and the camshaft spacer.





7. Install the camshaft thrust plate.
1 Position the camshaft thrust plate.
2 Install the bolts.





8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.





9. NOTE: If properly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and the camshaft keyway will be at 6 o'clock on the camshaft.

Install the bolts.





10. CAUTION: Make sure the components are installed in the correct location.

NOTE: Lubricate the crankshaft main bearings prior to installation.

Install the upper crankshaft main bearings and the upper crankshaft thrust main bearing.





11. CAUTION: The crankshaft journals must be protected from damage when installing the crankshaft.

Position the crankshaft.





12. NOTE: The main bearings are precision selective fit. Inspect the bearing clearance.

NOTE: If the rear main bearing cap is not installed within four minutes, remove the sealant and re-apply.

Clean the rear main bearing cap sealing area thoroughly and apply sealant to the rear main bearing cap-to-cylinder block parting line.

Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





13. Install the main bearing caps. Tighten the bolts in two stages:
- Stage 1: Tighten to 50 Nm (37 ft. lbs.).
- Stage 2: Rotate an additional 115 to 125°.





14. NOTE: Lubricate the crankshaft rear oil seal with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation.

Using the special tool, install the crankshaft rear oil seal.





15. Using the special tool, compress the piston ring.





16. CAUTION: Use care to avoid damage to the cylinder wall from the sharp edges of the connecting rod.

Install the piston with the arrow on the piston face pointing toward the front of the engine.
17. Inspect the piston clearance.





18. CAUTION: The connecting rod cap will fit only one way.

Position the lower connecting rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal.
19. Inspect the connecting rod bearing clearance.





20. Install the rod caps. Tighten the bolts in three stages:
- Stage 1: Tighten to 25 Nm (18 ft. lbs.).
- Stage 2: Tighten to 45 Nm (33 ft. lbs.).
- Stage 3: Tighten an additional 90-120°.
21. Install the remaining pistons and the connecting rods.





22. Install the oil pan baffle.





23. Install the oil pump screen cover and tube.





24. Install the timing chain tensioner.
1 Position the timing chain tensioner.
2 Install the bolts.





25. Retract the tensioner pad retracting mechanism.
1 Compress the tensioner pad retracting mechanism.
2 Insert a retaining pin.





26. Rotate the crankshaft so the number one piston is at Top Dead Center (TDC) and the key is at the 12 o'clock position.





27. Turn the camshaft sprocket so that the key is on the bottom of the balance shaft.





28. Install the timing chain, the camshaft sprocket and the crankshaft sprocket.





29. Make sure the timing marks and the keyways are aligned.





30. Install the camshaft position sensor drive gear.





31. Remove the retaining pin.





32. CAUTION: The components removed should be marked for location. Make sure the parts are installed in the correct location.

Install a new LH head gasket on the cylinder block with the small hole to the front of the engine and position the LH cylinder head.





33. CAUTION: Always use new bolts.

NOTE: Lubricate the bolts with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation.

Position the new bolts.
1 Position the new long bolts.
2 Position the new short bolts.





34. Tighten the bolts in the sequence shown in three stages:
- Stage 1: tighten to 20 Nm (15 ft. lbs.)
- Stage 2: tighten to 40 Nm (30 ft. lbs.).
- Stage 3: tighten to 50 Nm (37 ft. lbs.).





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

Tighten the bolts in sequence in four stages: short bolts numbered 2, 4, 6 and 8:
- Stage 1: tighten short bolts to 25 Nm (18 ft. lbs.).
- Stage 2: tighten an additional 180°.

Long bolts numbered 1,3,5 and 7:
- Stage 3: tighten long bolts to 45 Nm (33 ft. lbs.).
- Stage 2: tighten an additional 180°.
36. Repeat steps 32-35 for the RH cylinder head.





37. NOTE: Lubricate the push rods with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation.

Install the 12 push rods.
38. Install the 12 rocker arms.





39. Install the engine front cover and engine front cover gasket.
- Torque the bolts in the sequence shown.





40. NOTE: Lubricate the parts with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation.

Using the special tool, install the front crankshaft oil seal.





41. Install the crankshaft position sensor.
- Torque the bolts in the sequence shown.





42. Install the camshaft synchronizer.





43. NOTE: If the oil pan is not installed within four minutes, remove the sealer and re-apply.

Clean and apply the sealant to the oil pan sealing areas indicated and install the oil pan rear seal.
1 Apply the sealer to the rear main bearing cap. Install the oil pan rear seal.
2 Apply the sealer to the oil pan mating surface.
- Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





44. Install the oil pan. Tighten the bolts in the sequence shown in two stages:
- Stage 1: Tighten to 5 Nm (44 inch lbs.).
- Stage 2: Tighten to 10 Nm (89 inch lbs.).





45. Install the RH valve cover.





46. Install the LH valve cover.





47. Apply a bead of sealant to the keyway in the crankshaft damper and use the special tool to position and install the crankshaft pulley.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





48. Install the crankshaft pulley bolt.





49. Install the generator mounting bracket.





50. Install the power steering pump bracket.