Assembly

Special Tools:

NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure.

Note: Before engine assembly use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A and a suitable plastic or wooden scraper to clean sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.





1. Note: All crankshaft components must be lubricated before installation.

Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QDSP or equivalent meeting Ford specification WSS-M2C153-G. Install the crankshaft main bearings and the crankshaft thrust main bearing.





2. Note: The crankshaft main bearings are precise selective fit. Inspect bearing clearance.

Install the crankshaft.





3. Apply silicone rubber in two places.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





4. Install the crankshaft main bearing caps.





5. Tighten the four bolts and the four studs in pairs in two steps:
1 Tighten to 35 Nm (25 ft. lbs.).
2 Tighten to 97 Nm (72 ft. lbs.).





6. CAUTION: Place a rubber hose over the connecting rod studs to protect the crankshaft journals and cylinder walls from being damaged.

Note: Cylinder walls and piston must be lubricated. Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Note: Position the piston with the notch in the piston head toward the front of the engine.

Install the piston connecting rod assembly using a suitable piston ring compressor.





7. Install the connecting rod bearings.





8. Install the connecting rod caps.





9. Install the nuts and tighten in two steps.
1 Tighten to 20 Nm (15 ft. lbs.).
2 Tighten an additional 90 degrees.





10. Install the oil baffle assembly.





11. Install the oil pump shaft.





12. Install the oil pump.





13. Note: All camshaft components must be lubricated before installation; use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

If removed, use the Camshaft Bearing Service Set and install the camshaft bearings.





14. Install the camshaft.





15. Install the camshaft thrust plate.





16. Install the timing chain guide.





17. Install the camshaft sprocket and the crankshaft sprocket with the timing chain.





18. Verify the timing mark alignment.





19. Install the bolt.





20. Install the timing chain tensioner.





21. Install the oil filter adapter.





22. Note: Lubricate the valve tappets and bore with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the valve tappets.
23. Install new cylinder head gaskets.





24. Install the cylinder heads.





25. Note: The RH side is shown; the LH side is similar.

Install bolts and tighten in sequence shown in three steps:
1 Tighten to 32 Nm (24 ft. lbs.).
2 Tighten to 72 Nm (53 ft. lbs.).
3 Tighten an additional 90 degrees.





26. Install the push rods.





27. CAUTION: If the rocker arm shaft is not tightened gradually, the shaft may become bent during installation.

Install the RH and LH rocker arm shaft assembly and tighten in two steps:
1 Tighten to 32 Nm (24 ft. lbs.).
2 Tighten an additional 90 degrees.
28. Install the camshaft synchronizer.





29. Apply silicone rubber in four places.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
30. Install a new lower intake manifold gasket.





31. Install the lower intake manifold and tighten the bolts in sequence in four steps:
1 Tighten to 2 Nm (18 inch lbs.).
2 Tighten to 10 Nm (89 inch lbs.).
3 Tighten to 13 Nm (10 ft. lbs.).
4 Tighten to 12 Nm (12 ft. lbs.).





32. Note: The RH side is shown; the LH side is similar.

Apply sealer in two places.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





33. Note: The RH side is shown; the LH side is similar.

Install the RH and LH valve covers and new gaskets. Tighten the bolts in the sequence shown.





34. Install a new gasket and the front cover.





35. Apply silicone rubber in six places.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





36. Install a new gasket, the oil pan and tighten the bolts and the nuts in the sequence shown.





37. Install the bolts.





38. Install a new oil filter.
39. Install the crankshaft position (CKP) sensor.





40. Using the special tool, install the crankshaft pulley.





41. Note: This bolt is torque-to-yield and a new bolt must be installed.

Install a new bolt and tighten in two steps:
1 Tighten to 45 Nm (33 ft. lbs.).
2 Tighten an additional 90 degrees.





42. Install the wiring harness retainer bracket.





43. Install the RH and LH exhaust manifold gaskets, exhaust manifolds and tighten in the sequence shown.





44. Install the EGR outlet tube and bracket.





45. Connect the EGR valve tube to the exhaust manifold.





46. Install a new gasket and the EGR valve.





47. Install the water thermostat and the water hose connection.





48. Install a new gasket, the fuel injection supply manifold and tighten the studs in the sequence shown.





49. Install the bolt.





50. Position the vacuum harness and connect the line.





51. Position the engine control sensor wiring.





52. Note: Use Pipe Sealant with Teflon (R) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18p7-A on the threads.

Install the oil pressure sensor and connect the electrical connector.





53. Connect the camshaft position (CMP) sensor electrical connector.





54. Connect the fuel injector electrical connectors.





55. Connect the electrical connectors:
- engine coolant temperature (ECT) sensor
- water temperature indicator sender unit





56. Connect the crankshaft position (CKP) sensor electrical connector.
57. If removed, install a new intake manifold upper gasket.





58. Install the upper intake manifold.





59. Position the fuel line bracket.





60. Tighten the nuts in the sequence shown.

61. CAUTION: Correct installation of the spark plug wires is critical to vehicle operation. If one spark plug wire is not correctly installed on the spark plug or the ignition coil, both spark plugs connected to that segment of the ignition coil may not fire under load.

Note: Wipe the spark plug wires with a clean, damp cloth prior to inspection.

Note: When a spark plug wire is removed for any reason from a spark plug or ignition coil, or a new spark plug wire is installed, Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESA-MlC171-A must be applied to the spark plug wire boot prior to installation.

Coat the entire interior surface of the boot and connect the spark plug wires to the ignition coil and to the spark plugs.





62. Connect the radio ignition interference capacitor and the ignition coil electrical connectors.





63. Connect the throttle position (TP) sensor electrical connector.





64. Connect the canister purge line from the throttle body.





65. Connect the EGR transducer hoses.





66. Connect the crankcase ventilation tube.





67. Connect the vacuum lines to the:
- EGR solenoid.
- upper intake manifold.
- EGR valve.





68. Connect the engine control sensor wiring to the:
- idle air control (IAC) valve.
- EGR transducer.
- EGR solenoid.