Part 2

Engine




















a Early build vehicle cooling systems are filled with Motorcraft(R) Specialty Green Engine Coolant and late build vehicle cooling systems are filled with Motorcraft(R) Specialty Orange Engine Coolant. Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.

Lower Engine Block (View 1)










Lower Engine Block (View 2)










Front Engine Block










Cylinder Head










Intake Manifold









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 or 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.

28. 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 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 balancer unit.

- 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 the Balance Shaft Backlash Balance Shaft Backlash procedure.






29. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).


30. NOTE: The Crankshaft TDC (Top Dead Center) Timing Peg will contact the crankshaft and prevent it from turning past TDC (Top Dead Center). However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC (Top Dead Center) position until the timing drive components and crankshaft pulley are installed.
Install the Crankshaft TDC (Top Dead Center) Timing Peg.






31. Install the block-off plate and bolts.
- Tighten to 25 Nm (18 lb-ft).






32. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.
Install the oil pump assembly. Tighten the bolts in the sequence shown in the following 2 stages:

- Stage 1: Tighten to 10 Nm (89 lb-in).

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






33. Install a new oil pump pickup tube gasket and the pickup tube.
- Tighten to 10 Nm (89 lb-in).






34. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear oil seal with retainer.





35. Tighten the crankshaft rear oil seal with retainer bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).






36. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool and metal surface cleaner to remove traces of sealant.

Clean and inspect all mating surfaces.


37. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.


38. Install the oil pan and install the 2 oil pan bolts finger-tight.





39. Using a suitable straightedge, align the front surface of the oil pan flush with the front surface of the engine block.





40. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).






41. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.





42. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.

2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.

3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.


43. Apply silicone gasket and sealant to the locations shown.





44. Install a new head gasket.





45. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in the following 5 stages:

- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 15 Nm (133 lb-in).

- Stage 3: Tighten to 45 Nm (33 lb-ft).

- Stage 4: Turn 90 degrees.

- Stage 5: Turn an additional 90 degrees.






46. NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.


47. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
- Stage 1: Tighten 1 turn at a time until tight.

- Stage 2: Tighten to 7 Nm (62 lb-in).

- Stage 3: Tighten to 16 Nm (142 lb-in).






48. Install the Variable Camshaft Timing (VCT) system oil filter and plug in the intake camshaft thrust cap.
- Tighten to 17 Nm (150 lb-in).






49. Install the VCT (Variable Camshaft Timing) solenoid and the bolt.
- Tighten to 10 Nm (89 lb-in).






50. NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.

- The crankshaft sprocket flange must be facing away from the engine block.






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






52. Install the shoulder bolt.
- Tighten to 10 Nm (89 lb-in).






53. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
- Tighten to 10 Nm (89 lb-in).






54. NOTICE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.






55. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.