Steps 1-40

NOTE: Ford does not provide a procedure to align the timing components without the OE tools specified.


1. Lubricate and install the crankshaft upper main bearings into the cylinder block.
- Use Super Premium SAE 5W30 motor oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

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.





2. Install the crankshaft onto the upper main bearings.

NOTE: Do not install the upper thrust bearings until the crankshaft is installed. Refer to Step 3.





3. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.

NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).





4. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.

NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).





5. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.

NOTE:
- To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
- The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).








6. Install the crankshaft lower main bearings into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or dead-blow hammer.





7. Install the dowel pins so the flat sides face the crankshaft.





8. Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 37-43 Nm (27-32 ft. lbs.).
- Stage 2: Tighten an additional 85-95 degrees.





9. Install the side bolts and tighten in two stages, in the sequence shown.
- Stage 1: Tighten to 27-33 Nm(20-24 ft. lbs.).
- Stage 2: Tighten an additional 85-95 degrees.





10. Use the Connecting Rod Guide Tool and the Piston Ring Compressor to install the connecting rod with upper connecting rod bearing in place.

CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: Steps 13, 14 and 15 are for all eight connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.





11. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Guide Tool.

CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

12. Position the lower bearing and connecting rod, and install the new bolts loosely.

CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated properly.





13. Tighten the bolts in two stages, using the sequence shown.
- Stage 1: 40-45 Nm (30-33 ft. lbs.)
- Stage 2: Rotate 90-120 degrees





14. Install the RH engine mount and the three bolts.





15. Install the oil filter adapter.





16. Install the LH engine mount and the bolts.





17. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.





18. Position the (A) head gasket over the (B) dowel pins.
- RH is shown; LH is similar.

CAUTION: Make sure all coolant residue and debris are cleaned from the block surface and cylinder bore.





19. Rotate the crankshaft until the crankshaft keyway points toward the top of the engine (12 o'clock).





20. Position the (A) cylinder head over the dowels on the (B) head gasket and install the (C) cylinder head bolts loosely.
- RH is shown; LH is similar.

NOTE: Do not turn the crankshaft until instructed to do so.





21. Tighten the bolts in three stages, in the sequence shown.
RH is shown, LH is similar
- Stage 1: 37-43 Nm (27-32 ft. lbs.)
- Stage 2: Rotate 85-95 degrees
- Stage 3: Rotate 85-95 degrees





22. Install the oil level indicator tube.
- Install a new O-ring on the oil level indicator tube.
- Install the oil level indicator tube.
- Install the bolt.

NOTE: Lubricate O-ring with Super Premium SAE 5W30 motor oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





23. Install the RH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.





24. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.





25. Compress the tensioner plunger, using an edge of a vise.

CAUTION:
- Timing chain procedures must be followed exactly or damage to valves and pistons will result.
- Do not compress the ratchet assembly. This will damage the ratchet assembly.

NOTE: Ford does not provide a procedure to align the timing components without the OE tools specified.





26. Using a small screwdriver or pick, push back and hold the ratchet mechanism.





27. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





28. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
29. Remove the tensioner from the vise.





30. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.





31. Loosely install the Camshaft Holding Tools on both camshafts.





32. Install the timing chain guides.





33. Slightly loosen the Camshaft Holding Tool to allow slight camshaft movement. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Holding Tool to maintain camshaft pre-positioning.





34. Use the (A) Camshaft Positioning Tool to position the (B) camshaft.

CAUTION: Do not turn the engine over with the Camshaft Positioning Tool or damage to the camshaft sprocket or the bolt may occur.





35. Position the crankshaft with the Crankshaft Holding Tool.

CAUTION:
- Unless otherwise instructed, at no time when the timing chains/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
- Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur.

36. Remove the Crankshaft Holding Tool.





37. Position the inner crankshaft sprocket with the long hub facing outward.





38. Install the LH timing chain/belt to the crankshaft sprocket, aligning the one copper link on the timing chain/belt with the slot on the crankshaft sprocket.





39. Position the timing chain/belt on the camshaft sprocket with the two copper chain links and the camshaft sprocket timing mark aligned.

NOTE:
- make sure the upper half of the timing chain/belt is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust.
- If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.





40. Position the outer camshaft sprocket and the RH timing chain/belt with the long hub of the sprocket facing inward.

CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured.

NOTE:
- Be sure the copper chain link and crankshaft sprocket timing mark are aligned.
- The lower half of the timing chain/belt must be positioned above the dowel.