Part 1

Engine














Engine - External Components










Engine - Front and Upper Components










Engine - Lower Block Components









NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

1. Install the 4 engine piston oil coolers and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).






2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.





3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.





4. Tighten the 10 original main bearing beam bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 25 Nm (18 lb-ft).

- Stage 3: Tighten an additional 90 degrees.






5. Measure each crankshaft block main bearing bore diameter.





6. Using the chart, select the crankshaft main bearings.





7. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 29 Nm (21 lb-ft).

- Stage 3: Tighten an additional 90 degrees.






8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
- Remove the bolts and the connecting rod cap.

- Discard the connecting rod cap bolts.






9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.





10. NOTE: Mixed grade bearing pairs (green/blue, blue/red, red/brown) can be installed in upper or lower positions. It is not necessary to maintain specific position.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.






11. Remove the 10 bolts in the sequence shown and the main bearing beam.
- Discard the main bearing beam bolts.






12. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

NOTE: The center bulkhead is the thrust bearing.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.






13. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.






14. NOTE: Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.






15. Lubricate the 10 main bearing beam side fit surfaces and the 5 main bearing beam bearings with clean engine oil.





16. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.





17. NOTE: Lubricate the main bearing beam bolt threads and under the bolt heads with clean engine oil.

NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

Install and tighten the 10 new main bearing beam bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 25 Nm (18 lb-ft).

- Stage 3: Tighten an additional 90 degrees.






18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
1. Position the crankshaft to the rear of the cylinder block.

2. Zero the Dial Indicator Gauge with Holding Fixture.

3. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.

4. Acceptable crankshaft end play is 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.






19. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.
Install the 4 upper bearings in the connecting rods and install the 4 lower bearings into the connecting rod caps.

- Lubricate the connecting rod bearings with clean engine oil.






20. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

NOTE: Lubricate the pistons, piston rings and the entire cylinder bores with clean engine oil

Using the Piston Ring Compressor, install the 4 piston and connecting rod assemblies.
- When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.

- The position of the upper and lower compression ring gaps are not controlled for installation.






21. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

Install the 4 connecting rod caps and the 8 new bolts and tighten the bolts in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 29 Nm (21 lb-ft).

- Stage 3: Tighten an additional 90 degrees.






22. Install the Crankshaft TDC (Top Dead Center) Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC (Top Dead Center) Timing Peg. The engine is now at TDC (Top Dead Center).





23. NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.

NOTE: The original adjustment shims must be installed in their original positions.

NOTE: Confirm by visual inspection that there is no damage to the balance shaft assembly gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balance shaft assembly.

Install the adjustment shims in their original positions on the seat faces of the balance shaft assembly.
- With the balance shaft assembly marks in the TDC (Top Dead Center) position, slowly install the balance shaft assembly onto the cylinder block to avoid interference between the crankshaft drive gear and the balance shaft assembly driven gear.






24. Install the 4 balance shaft assembly bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten to 42 Nm (31 lb-ft).






25. Remove the Crankshaft TDC (Top Dead Center) Timing Peg.
- Rotate the crankshaft to confirm that there are no meshing problems between the balance shaft assembly gear and the crankshaft gear.






26. Install the Crankshaft TDC (Top Dead Center) Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC (Top Dead Center) Timing Peg. The engine is now at TDC (Top Dead Center).
- Remove the TDC (Top Dead Center) Timing Peg.






27. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.

NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft assembly housing.

NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown.

Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
- Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balance shaft assembly.

- Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.

- Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).

- If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. For additional information, refer to Balance Shaft Backlash.






28. Install the Crankshaft TDC (Top Dead Center) Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC (Top Dead Center) Timing Peg. The engine is now at TDC (Top Dead Center) and must remain at the TDC (Top Dead Center) position until the timing drive components and crankshaft pulley are installed.





29. NOTE: Clean the oil pump and cylinder block mating surfaces with Motorcraft(R) Metal Surface Prep.
Install the oil pump assembly.

- Tighten the 4 bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).







30. Install the oil pump sprocket and bolt.
- Tighten to 25 Nm (18 lb-ft).






31. Install the diamond washer.





32. Install the crankshaft sprocket.





33. Install the chain on the oil pump sprocket.
1. Install the tensioner and the 2 shoulder bolts.
- Tighten to 10 Nm (89 lb-in).

2. Push the tensioner spring down and position the spring under the shoulder bolt.






34. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
- Install the 6 bolts and tighten in the sequence shown to 10 Nm (89 lb-in).

- Remove the Crankshaft Rear Main Oil Seal Installer.






35. Using a new gasket, install the oil pump screen and pickup tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).