Steps 1 - 65

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.

Special Tools:

NOTE: Before engine assembly, use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.





1. Install the crankshaft main bearings.
- Lubricate the crankshaft main bearings with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





2. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance.

Install the crankshaft.





3. NOTE: The rear main bearing cap must be installed within four minutes after applying the silicone.

Apply sealant to the rear main bearing cap to cylinder block parting line.
- Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6.
4. Install the crankshaft main bearings in the main bearing caps.





5. Install the main bearing caps.





6. Tighten the bolts.
7. Lubricate the piston rings.
- Use with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
8. Make sure that the piston rings are properly spaced.





9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.









10. NOTE:Position the piston with the indentation arrow toward the front of the cylinder block.

Using the special tool, install the pistons.

11. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.

Check the clearance of each connecting rod bearing.

12. Rotate the crankshaft until the piston is at the bottom of its stroke.





13. NOTE: For cylinders 1,2 and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5 and 6, remove the opposite nut first.

Loosen the first nut until the face is approximately 2 mm over the end of the bolt.





14. Tap the bolt on the nut until it can be removed by hand.
15. Repeat previous two steps for the opposite bolt.





16. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.
17. Install the connecting rod cap in the original position.





18. NOTE: Do not exceed 20 Nm when tightening the connecting rod nuts.

Install and tighten the connecting rod nuts until they touch the connecting surface of the Connecting rod cap.
19. Tighten the connecting rod nuts simultaneously in two steps:
- Step 1: 20 Nm.
- Step 2: 90°.
20. Repeat previous four steps for the remaining connecting rods.





21. Rotate crankshaft until No. 1 piston is at top dead center.

CAUTION: To align any chains you MUST use the special service tools. Ford does not provide timing marks or any additional information for repair or replacement of the timing chains without the special tools listed.





22. On 4 x 4 vehicles, install the balance shaft.
1 Install the balance shaft assembly.
2 Install the bolts.





23. On 4 x 4 vehicles, install the balance shaft chain and crankshaft sprocket.





24. NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete turns of the balance shaft may be required to find the correct position.

On 4 x 4 vehicles, align the timing marks.
- Install the 4 mm pin to hold the shaft in place.





25. On 4 x 4 vehicles, install the balance shaft tensioner.
1 Install the balance shaft tensioner.
2 Install the bolts.
3 Position the balance shaft chain guide and install the two bolts.
4 Remove the pin from the tensioner.





26. Install the oil pump.





27. Install the jackshaft.





28. Install the jackshaft thrust plate and bolts.





29. Install the oil pump drive.





30. Attach the rear cassette and sprocket to the jackshaft. Install the bolt. Do not tighten at this time.





31. Install the rear cassette and bolt.





32. Install the front cassette and bolt.





33. Position the jackshaft sprocket and chain.





34. Install the chain guide.





35. Install the chain tensioner.





36. Install the bolt. Do not tighten at this time.
37. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt to 20 Nm (15 ft. lbs.).





38. Install the special holding tool on the rear of the jackshaft.





39. Tighten the rear bolt an additional 90°.





40. Tighten the front bolt.
- Step 1: Tighten to 45 Nm (33 ft. lbs.).
- Step 2: Rotate an additional 90°.





41. Remove the special tool and install rear jackshaft plug.





42. Position the front cover gasket and install the front cover.





43. Apply silicone gasket and sealant to the front cover in four places.





44. Apply silicone gasket and sealant to the rear main bearing cap as shown.
- Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6.
- Position the ladder frame gasket.





45. CAUTION: The ladder frame inserts must be loosened completely or damage to the ladder frame and/or oil leaks may result.

Loosen the ladder frame inserts.





46. Position the ladder frame and gasket assembly.





47. Install and hand-tighten the fifteen bolts and 2 nuts.





48. Install and hand-tighten the bolts.





49. NOTE: The ladder frame to cylinder block alignment must be within a maximum mismatch of 0.25mm (0.01 in) ladder frame underflush or 0.05 mm (0.00196 in) ladder frame protrusion.

Using a straightedge, align the transmission face of the ladder frame with the rear face of the cylinder block.





50. Install the fifteen bolts and two nuts.





51. Tighten the bolts.





52. Tighten the inserts.





53. Install new seals on the two silver M8 bolts and position them in the #5 and #6 position.





54. Position the six remaining ladder frame bolts in positions 1, 2, 3, 4, 7 and 8.





55. Install the ladder frame bolts in two steps.
- Step 1: Tighten to 15 Nm (11 ft. lbs.).
- Step 2: Tighten to 33 Nm (24 ft. lbs.).





56. NOTE: Assemblies that measure out of specification must have the entire assembly procedure repeated.

Measure the step between the rear face of the cylinder block and the transmission face of the ladder frame.





57. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the ladder frame.





58. NOTE: Clean the gasket mating surfaces with metal surface cleaner.

Install a new gasket and the oil pump screen and pickup tube.





59. Install the gasket and oil pan.





60. Install the oil filter adapter.





61. Install the oil filter.





62. NOTE: LH side shown, RH similar.

Position the cylinder head gasket and the cylinder head.





63. NOTE: LH cylinder head shown, RH similar.

Install the eight 12mm bolts and tighten to 35 Nm (26 ft. lbs.) in the sequence shown.





64. NOTE: LH cylinder head shown, RH similar.

Install the two 8 mm bolts.





65. NOTE: LH cylinder head shown, RH similar.

Tighten the eight 12 bolts in sequence shown.
1 Rotate 90°.
2 Rotate an additional 90°.