Part 1 of 2

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.






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. Install the (A) camshaft and the (B) 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 lines up with the timing mark on the engine balance shaft drive gear.





9. Note: If correctly 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.

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





12. Note: If the rear main bearing cap is not installed within four minutes, remove the sealant and reapply.

Clean the rear main bearing cap sealing area thoroughly and apply sealant to the (A) 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. Use a piston ring compressor to compress the piston ring.





16. CAUTION: Inspect the piston clearance.

CAUTION: Do not damage the cylinder wall with 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. CAUTION: Inspect the connecting rod bearing clearance.

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

Position the (A) lower connecting rod bearing and the (B) connecting rod cap on the connecting rod and the crankshaft journal.





18. Install the rod caps. Tighten the rod cap 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°

19. Install the remaining pistons and the connecting rods.





20. Install the oil pan baffle.
- Install the nuts.





21. Install the oil pump screen cover and tube.
- Install the new gasket.
- Position the oil pump screen cover and tube.
- Install the bolts.
- Install the nut.





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





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





24. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at the 12 o'clock position.





25. Turn the balance shaft drive gear so that the key is on the bottom of the camshaft.





26. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.





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





28. Install the camshaft position sensor drive gear.
- Position the camshaft position sensor drive gear.
- Install the bolt.





29. Remove the retaining pin.

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





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





31. CAUTION: Always use new bolts.

Note: Lubricate the bolts with Super Premium SAE 5W30 Motor Oil XO-10W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation. Refer to the location note made during removal and make sure the bolts are installed in the correct location.
Install the new bolts.
1 Install new long bolts
2 Install new short bolts





32. Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten to 20 Nm (14 ft. lbs.)
- Stage 2: Tighten to 40 Nm (29 ft. lbs.)
- Stage 3: Tighten to 50 Nm (36 ft. lbs.)





33. 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 to 25 Nm (18 ft. lbs.).
- Stage 2: Tighten an additional 175-185°. Long bolts numbered 1, 3, 5 and 7:
- Stage 3: Tighten to 45 Nm (33 ft. lbs.)
- Stage 4: Tighten an additional 175-185°





34. Note: Lubricate the valve tappets with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installing.

Install the valve tappets.
- Install the valve tappets. Install the tappet guide plates and retainers.
- Install the bolts.





35. Note: Lubricate the push rods with Super Premium SAE 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation.

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





37. Install the engine front cover and engine front cover gasket.
1 Position a new engine front cover gasket and the engine front cover on the dowels.
2 Install the stud bolts.
3 Install the bolt.
4 Install the screw.





38. Note: Lubricate the parts with Super Premium SAE5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G before assembly.

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





39. Install the crankshaft position sensor.





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





41. Install the crankshaft pulley bolt.
42. Install the camshaft synchronizer.





43. Note: Install a new water pump gasket.

-Install the water pump.
1 Install the nuts.
2 Install the bolts.





44. Install the water pump pulley.
Install the bolts.





45. Install the oil pressure sensor extension.





46. Note: If the oil pan is not installed within four minutes, remove the sealer and reapply.

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.
2 Install the oil pan rear seal.
3 Apply the sealer to the oil pan mating surface.
- Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





47. Tighten the oil pan bolts in the sequence indicated.





48. Install the oil pressure sensor.





49. Install a new oil bypass filter.
- Tighten to one-half turn after the gasket contacts the sealing surface.





50. Note: Inspect the valve cover gaskets for damage.
- Install new gasket, if necessary.
- Install the valve covers.
1 Position the valve covers.
2 Install the bolts.
3 Install the stud bolts.