Steps 1 - 49

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

Special Tools:

1. 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.

Lubricate and install the crankshaft upper main bearings into the cylinder block.
- Use Super Premium 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

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

On Romeo engines, install the crankshaft onto the upper crankshaft main bearing.

On Windsor engines, install the crankshaft onto the upper main bearings.

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

On Windsor engines, push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.

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

On Windsor engines, push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.

5. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

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

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

On Romeo engines, install the rear main bearing cap.

All Vehicles

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. On Romeo engines, tighten the jack screws in two stages, in the sequence shown.
- Stage 1: Tighten to 5 Nm (44.6 inch lbs.)
- Stage 2: Tighten to 9-11 Nm (80-97 inch lbs.)

8. On Windsor engines, install the dowel pins so the flat sides face the crankshaft.

9. On Romeo engines, install the bolts and tighten in two stages in the sequence shown.
- Stage 1: Tighten to 10 Nm (89.2 inch lbs.).
- Stage 2: Tighten to 19-23 Nm (14-17 ft. lbs.).

10. On Windsor engines, 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°.

11. On Romeo engines, tighten the bolts in the sequence shown.

12. On Windsor engines, 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°.

13. 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.

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

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

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

15. 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.

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

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

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

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

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

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

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

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.

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°.
- Stage 3: Rotate 85-95°.

22. NOTE: Lubricate O-ring with Super Premium 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

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.

23. Install the RH exhaust manifold gaskets and the exhaust manifold. 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. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

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

CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

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

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

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

35. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur.

Position the crankshaft with the Crankshaft Holding Tool.
36. Remove the Crankshaft Holding Tool.

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

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

39. NOTE: Make sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust.

NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

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

40. 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.

NOTE: The lower half of the timing chain must be positioned above the dowel.

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

41. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment with the Camshaft Positioning Tool.

Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark.

42. As a post-check, verify proper alignment of all timing marks.

43. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the bolts.

44. Remove both the RH and LH pins from the timing chain tensioner assembly.

45. Remove the Camshaft Holding Tools.

46. NOTE: Romeo Timing Procedure
Install the timing chain guides.
1 Position LH timing chain guide.
2 Install and tighten the bolts.
3 Position the RH timing chain guide.
4 Install and tighten the RH bolts.

47. Install the timing chains and crankshaft sprockets.
1 Slide the (A) crankshaft sprocket onto the (B) crankshaft, aligning the copper link on the timing chain with the dot on the crankshaft sprocket.
2 Position the timing chain over the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket.

48. Make sure that the (A) copper marks on the timing chains are lined up with the corresponding dots on the crankshaft sprockets and camshaft sprockets.

49. Make sure that the (A) camshaft sprocket keyway is 90 degrees from the (B) valve cover mounting surface.