Assembly

NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.

1. Install the upper crankshaft main bearings into the cylinder block.

NOTE: Clean and inspect the crankshaft main bearings.

2. Carefully install the crankshaft in the cylinder block.
3. Install the lower crankshaft main bearings into the crankshaft main bearing cap.

NOTE: Measure the crankshaft main bearing oil clearance.





4. Install the crankshaft main bearing cap. Tighten the eight crankshaft main bearing cap bolts in two steps in the sequence shown to 90-100 Nm (67-74 ft. lbs.).





5. Slip two pieces of snug-fitting rubber hose over the connecting rod bolts to prevent bolt-to-crankshaft journal contact during installation.





6. Prior to installing the pistons in the engine, ensure that the indent on the top of the piston and the W on the front of the piston and the connecting rod are facing forward. Also check that the number on the connecting rod matches up with the cylinder number.

NOTE: Clean and inspect the pistons and connecting rods.

NOTE: Installation of the pistons is easier if the crankshaft journal is in the bottom dead center (BDC) position.





7. Properly align the piston rings. Dip the piston into clean engine oil.





8. Install Piston Ring Compressor 303-D032 (D81L-6002-C) or equivalent onto the pistons. Use a hammer handle or piece of wood to tap the piston and connecting rod into the cylinder bore. Guide the connecting rod bolts over the crankshaft journal.
9. Remove the rubber hoses from the connecting rod bolts.
10. Coat the upper half of the connecting rod bearing with clean engine oil and install the upper half of the connecting rod bearing.

NOTE: Clean and inspect the connecting rod caps.

NOTE: Check the connecting rod bearing oil clearance.

11. Coat the lower half of the connecting rod bearing with clean engine oil and install the lower half of the connecting rod bearing into the connecting rod caps.
12. Install the connecting rod caps.
13. Tighten the connecting rod nuts as follows:
(1) Tighten the connecting rod nuts to 14-16 Nm (10-12 ft. lbs.).
(2) Tighten the connecting rod nuts to 38-44 Nm (28-33 ft. lbs.).

14. Install a new crankshaft rear main cover gasket on the crankshaft rear main oil seal cover.
15. Install the crankshaft rear main oil seal cover on the cylinder block. Tighten the crankshaft rear main oil seal cover bolts to 8 Nm (70 in. lbs.).
16. Install a new oil pump gasket on the oil pump.





17. Position the oil pump on the front of the engine. Tighten the long oil pump bolts to 12-16 Nm (9-12 ft. lbs.) and the short oil pump bolts to 6-7 Nm (53-62 in. lbs.).
18. Install a new oil pump inlet tube gasket on the oil pump screen cover and tube.
19. Position the oil pump screen cover and tube on the oil pump and install the oil pump screen cover and tube bolts. Tighten the oil pump screen cover and tube bolts to 16-21 Nm (12-15 ft. lbs.).
20. Install two new oil filter adapter O-rings on the oil filter adapter.
21. Position the oil filter adapter on the oil pump and install the three oil filter adapter bolts. Tighten the three oil filter adapter bolts to 16-21 Nm (12-15 ft. lbs.).





22. Install new oil pan seals. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to the oil pan seals as shown.

NOTE: Ensure that the oil pan and cylinder block mating surfaces are clean of any old sealant material.





23. Apply a bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to the oil pan as shown.





24. Install the oil pan on the cylinder block. Tighten the 18 oil pan bolts in the sequence shown to 7-8 Nm (62-70 in. lbs.).
25. Install the crankshaft keys, the inner timing chain/belt guide, the crankshaft sprocket, and the outer timing chain/belt guide.





26. Install a continuous 2.0-3.0 mm (0.079-0.118 inch) wide bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 on the water pump and position the water pump on the cylinder block.

NOTE: Ensure the mating surfaces between the water pump and the cylinder block are cleaned of any sealant material.

27. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-16 ft. lbs.).
28. Install the timing chain/belt tensioner and timing chain/belt tensioner spring. Tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 ft. lbs.).
29. Install new head gaskets on the cylinder heads.





30. Position the cylinder heads on the cylinder block and install new cylinder head bolts. Tighten new cylinder head bolts as follows:
a. Tighten the cylinder head bolts in the sequence shown to 29 Nm (22 ft. lbs.).
b. Tighten the cylinder head bolts in the sequence shown to 59 Nm (43 ft. lbs.).






c. Loosen all the bolts completely using the loosening sequence shown.
d. Tighten the cylinder head bolts in the tightening sequence shown to 29 Nm (22 ft. lbs.).
e. Turn all cylinder head bolts 60 to 65 degrees. If a torque angle wrench is not available tighten the cylinder head bolts in the sequence shown to 54-64 Nm (40-47 ft. lbs.).
f. Install the cylinder head bolt at position A as shown in the tightening sequence. Tighten the cylinder head bolt (A) to 9-12 Nm (80-104 in. lbs.).

NOTE: Cylinder head bolts 4, 5, 12, and 13 are 127 mm (5.00 inches). The rest of the cylinder head bolts are 106 mm (4.17 inches).

31. Position the rocker arm shaft supports on the cylinder heads.





32. Remove the mechanic's wire from the valve tappets.
33. Install the rocker arm shaft and rocker arm assembly on the rocker arm shaft support.
34. Rotate the camshaft until the valve tappets for the respective rocker arm shaft assembly are not being lifted.
35. Install the rocker arm shaft bolts. Tighten the rocker arm shaft bolts in two steps to 18-22 Nm (13-16 ft. lbs.).
36. Install a new valve cover gasket on the valve covers.
37. Install the valve covers on the cylinder heads. Tighten the 18 front valve cover and rear valve cover screws to 1-3 Nm (9-26 in. lbs.).
38. Install new exhaust manifold gaskets on the exhaust manifolds and position the exhaust manifolds on the cylinder heads.








39. Tighten the exhaust manifold nuts in two steps in the sequences shown to 18-22 Nm (13-16 ft. lbs.).
40. Install the transmission fluid level indicator tube heat shield.
41. Install the two nuts and one bolt securing the rear exhaust manifold crossover tube to the front exhaust manifold. Tighten the rear exhaust manifold crossover tube-to-front exhaust manifold nuts and bolt.
42. Install the two oil level indicator tube bracket bolts and the oil level indicator tube. Tighten the two oil level indicator tube bracket bolts 8-10 Nm (71-88 in. lbs.).
43. Clean all of the old sealant from the thermostat housing.
44. Apply a fresh bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to the thermostat housing. Position the thermostat housing and coolant crossover tube on the engine.
45. Install the two thermostat housing bolts. Tighten the thermostat housing bolts to 16-21 Nm (12-15 ft. lbs.).
46. Install the coolant crossover tube bolts. Tighten the coolant crossover tube bolts to 21 Nm (15 ft. lbs.).
47. Install the seal plate. Tighten the seal plate bolts to 3-5 Nm (27-44 in. lbs.).





48. Install the camshaft sprocket, camshaft sprocket washer and camshaft sprocket retaining bolt on the front of each camshaft.

NOTE: The camshaft sprockets are marked with L3 to designate the LH camshaft sprocket and R3 to designate the RH camshaft sprocket.





49. Use Cam Sprocket Holding/Removing Tool 303-098 (T74P-6256-B) to hold the camshaft sprocket. Tighten the camshaft sprocket retaining bolt to 78-88 Nm (58-65 ft. lbs.).





50. If the timing marks do not line up correctly, turn either of the camshafts or the crankshaft to line up the marks.

NOTE: Ensure that the timing marks on the camshaft sprockets are aligned with the marks on the rear engine front cover. Also check that the timing mark on the crankshaft is aligned with the mark on the oil pump housing.

51. Install the timing chain/belt starting at the crankshaft sprocket and moving around to the camshaft sprockets in a counterclockwise direction. Do not allow any slack in the timing chain/belt between the crankshaft sprocket and camshaft sprockets. After all of the timing marks are matched up with the timing chain/belt installed, slip the timing chain/belt onto the timing chain/belt tensioner.






CAUTION: Pay special attention to the tooth shape of the timing chain/belt. The current timing chain/belts are not interchangeable with the timing chain/belts from the 1993 model year. The 1993 model year uses a square or trapezoidal tooth timing chain/belt while the current model year uses a rounded tooth design. The design change was made to extend the service life of the timing chain/belt from 60,000 miles for the square or trapezoidal toothed belt to 105,000 miles for the rounded tooth belt. If the proper timing chain/belt is not used, the customer may complain of a "whining" noise coming from the engine compartment. If the camshaft sprocket has a square cut in the valley of the gear tooth, it will require a square or trapezoidal tooth timing chain/belt. If the camshaft sprocket has a rounded cut in the valley of the gear tooth, it will require a rounded tooth timing chain/belt.

(Part 2 Of 2):

NOTE:
- If a new timing chain/belt is to be installed, make sure that the arrow is pointing away from the engine. If a timing chain/belt is to be reused, make sure that the directional arrow that was marked during disassembly is facing the correct direction.
- A new timing chain/belt has three white timing marks that indicate the correct timing positions of the camshafts and the crankshaft. These marks will help ensure that the engine is timed properly. When the engine is properly timed each white timing mark on the timing chain/belt will be aligned with the corresponding camshaft and crankshaft timing mark on the crankshaft sprocket and the camshaft sprockets. Because the white timing marks are not evenly spaced you will need to refer to the illustration for proper timing chain/belt placement. There should be 40 timing belt teeth between the timing marks of the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket.
- Verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump.

52. Install the timing chain/belt.
53. While holding the timing chain/belt tensioner with an Allen wrench, loosen the timing chain/belt tensioner nut.
54. Allow the timing chain/belt tensioner to put pressure on the timing chain/belt.





55. Use an Allen wrench to turn the timing chain/belt tensioner 70-80 degrees clockwise and tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 ft. lbs.).
56. Rotate the crankshaft sprocket clockwise twice and align the No. 1 piston to Top Dead Center (TDC) on its compression stroke.

CAUTION: Rotate the crankshaft clockwise. Damage to the engine may occur if the crankshaft is turned counterclockwise.





57. Apply 98 N (22 lbs) of force on the timing chain/belt between the rear camshaft sprocket and the timing chain/belt tensioner.





58. While holding the timing chain/belt tensioner steady with an Allen wrench, loosen the timing chain/belt tensioner nut and proceed as follows:
a. Install a 0.35 mm (0.0138 inch) thick and 12.7 mm (0.500 inch) wide feeler gauge as shown.





b. Turn the crankshaft sprocket clockwise to position the feeler gauge between the timing chain/belt tensioner Timing chain/belt tensioner and the timing chain/belt.
c. Tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 ft. lbs.).
d. Turn the crankshaft sprocket clockwise to remove the feeler gauge from between the timing chain/belt tensioner and the timing chain/belt.
59. Rotate the crankshaft sprocket clockwise twice and align the No. 1 piston to Top Dead Center (TDC) on its compression stroke.





60. Apply 98 N (22 lbs) of force on the timing chain/belt between the rear and front camshaft sprocket.
61. Measure the timing chain/belt deflection. Timing chain/belt deflection should be between 13-15 mm (0.51-0.59 inch). If timing chain/belt deflection is not within specification, repeat the timing chain/belt adjustment procedure. If the timing chain/belt cannot be adjusted to within the specification the timing chain/belt will have to be replaced.
62. Install the lower engine front cover and the five lower engine front cover bolts. Tighten the lower engine front cover bolts to 3-5 Nm (27-44 in. lbs.).
63. Position the upper engine front cover and the eight upper engine front cover bolts. Tighten the upper engine front cover bolts to 3-5 Nm (27-44 in. lbs.).
64. Install the timing chain/belt guide and the crankshaft pulley.





65. Use Strap Wrench 303-D055 (D85L-6000-A) or equivalent to hold the crankshaft pulley. Tighten the crankshaft pulley bolt to 191-211 Nm (141-156 ft. lbs.).





66. Use Strap Wrench 303-D055 (D85L-6000-A) or equivalent to hold the water pump pulley. Tighten the water pump pulley bolts to 16-21 Nm (12-15 ft. lbs.).





67. Install the knock sensor. Tighten the knock sensor bolt to 25-34 Nm (18-25 ft. lbs.).
68. Install new lower intake manifold gaskets on the cylinder heads and position the lower intake manifold on the cylinder block.
69. Install the Allen head intake manifold-to-cylinder block nuts and bolts and the intake manifold washers on the lower intake manifold.





70. Tighten the Allen head lower intake manifold nuts and bolts in the sequence shown in the following steps:
a. Tighten the intake manifold-to-cylinder block nuts and bolts to 3-5 Nm (26-44 in. lbs.).
b. Tighten the intake manifold-to-cylinder block bolts to 13-17 Nm (9-12 ft. lbs.) and the nuts to 24-27 Nm (17-20 ft. lbs.).
c. Tighten the intake manifold-to-cylinder block bolts to 13-17 Nm (9-12 ft. lbs.) and the nuts to 24-27 Nm (17-20 ft. lbs.).

71. Install the upper engine front cover bolt which is attached to the water hose connection. Tighten the upper engine front cover bolt to 3-5 Nm (27-44 in. lbs.).
72. Install the water bypass hose between the water hose connection and the thermostat housing.
73. Install the fuel injection supply manifold, fuel injector spacers, fuel injector insulators, and fuel injectors as an assembly.
74. Install the four Allen head fuel injection supply manifold bolts. Tighten the fuel injection supply manifold bolts to 24-27 Nm (17-20 ft. lbs.).





75. Connect the six fuel injector electrical connectors.
76. Install a new distributor base gasket on the distributor.





77. Apply clean engine oil to the new distributor base gasket and install the distributor.

NOTE: Align the mark on the distributor shaft to the protruding mark on the housing.








78. Ensure that the distributor rotor is aligned as shown. If the distributor rotor is misaligned, remove the distributor, turn the distributor rotor one tooth and reinstall.
79. Once the distributor rotor is aligned correctly, install the distributor hold-down bolt. Tighten the distributor hold-down bolt to 14-17 Nm (10-12 ft. lbs.).
80. Install a new intake manifold upper gasket on the lower intake manifold.
81. Position the upper intake manifold on the lower intake manifold and install the five Allen head upper intake manifold to lower intake manifold bolts. Tighten the upper intake manifold to lower intake manifold bolts to 18-22 Nm (13-16 ft. lbs.).
82. Connect the front breather hose on the front valve cover.





83. Install the two front breather tube bracket-to-upper intake manifold bolts.
84. Connect the rear breather hose to the rear valve cover.
85. Install the crossover breather tube and the crossover breather tube bracket bolt on the upper engine front cover.
86. Position the main engine wiring harness on the cylinder block and install the main engine wiring harness bracket-to-upper intake manifold bolts on the upper intake manifold.
87. Connect the coolant hose onto the side of the throttle body.
88. Connect the fuel pressure regulator-to-upper intake manifold vacuum hose to the fuel pressure regulator.
89. Connect the fuel tubes.
90. Connect the coolant hose on the IAC-FIC assembly.
91. Connect the IAC solenoid electrical connector.
92. Connect the FIC solenoid electrical connector.
93. Connect the PCV hose onto the rear valve cover.
94. Install the EGR valve to exhaust manifold tube onto the EGR valve and the rear exhaust manifold.
95. Position the distributor cap, with distributor to spark plug wires still attached, on the distributor and tighten the three distributor cap screws.
96. Install the distributor to spark plug wires on the spark plugs in correct order as noted during assembly.