Assembly

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

1. Measure the crankshaft main bearing clearance.
2. Measure the crankshaft end play.
3. Measure the camshaft bearing clearance.
4. Measure the camshaft end play.
5. Measure the crankshaft.
6. Measure the camshafts.
7. Measure the cylinder bores.
8. Measure the pistons.
9. Measure the piston ring gaps.
10. Measure the piston ring axial clearance.
11. Check the cylinder head distortion.

NOTE:
- The main bearing shells are color coded.
- Do not tighten the main bearing cap bolts yet.





12. Position the crankshaft.
1 Position the crankshaft in place.
2 Install the main bearing caps.
- Size A: 2.1445 mm (green)
- Size B: 2.1415 mm (brown)
- Size C: 2.1365 mm (yellow)
- Size D: 2.1315 mm (blue)
- Position the main bearing shells into the cylinder block and the main bearing caps in place, and coat them with Engine Assembly Lubricant D9A2-19579-D or equivalent meeting Ford specification ESR-M99C80-a

NOTE:
- The connecting rods are numbered starting from the timing belt end. The connected valve recesses on the piston crown are on the intake side.
- Do not tighten the connecting rod bearing cap bolts.





13. Install the pistons using Piston Ring Compressor.
- Lubricate the pistons and cylinder bores with engine oil .
- Distribute the piston ring gaps and the elements of the oil scraper ring evenly around the circumference 120° of the piston.
- Compress the piston rings using Piston Ring Compressor.
- Press pistons 1 and 4 into the cylinders using a wooden handle. Connecting rod bearing journals 1 and 4 must be at BDC.
- Check that the bearings for cylinders numbers 1 and 4 are clean and dry and install them in the connecting rods and bearing caps.
- Install the bearing caps.
- Rotate the crankshaft 180° and install pistons 2 and 3.
- Check that the bearings for cylinders number 2 and 3 are clean and dry and install them in the connecting rods and bearing caps.

NOTE: The crankshaft must rotate freely. If necessary, check and adjust the bearing clearances.






14. Install the main bearings and connecting rod bearings.
1 Tighten the bolts.
2 Tighten the nuts in two stages.
- Stage one: 35 Nm
- Stage two: 90 degree rotation

NOTE: Install a new seal on the oil seal carrier prior to oil seal carrier installation.





15. Install the rear oil seal carrier and the crankshaft position (CKP) sensor.
- Install a new oil seal in the carrier, position the carrier on the crank, and install the bolts finger tight.

1 Align the oil seal carrier so that the mating face of the oil seal carrier is between 0.3 mm and 0.8 mm below the cylinder block.
2 Tighten the four bolts.
3 Install the CKP sensor and bracket.






16. Install the oil seal.
- Install the oil seal using Crankshaft Rear Seal Replacer and three flywheel bolts.

NOTE: Install a new gasket on the oil pump prior to oil pump positioning.





17. Position the oil pump.
- Position the oil pump and install the bolts finger tight.
- Using a Feeler Gauge, align the oil pump on both sides so that the mating face is between 0.3 mm and 0.8 mm below the cylinder block.





18. Install the oil pump bolts.
- Tighten the bolts and check the alignment using Feeler Gauge so that the mating face is between 0.3 mm and 0.8 mm below the cylinder block. Correct as necessary.
19. Install a new crankshaft front oil seal.

NOTE: Use a new gasket during lower crankcase installation.





20. Align the lower crankcase.
- Coat the joints between the cylinder block and the oil pump with Silicone Gasket and Sealant F6AZ-19562-AA meeting Ford specification WSE-M4G323-A6.
- Position the lower crankcase and gasket and install the bolts finger tight.
- Align the lower crankcase using a Straight Edge so that the cylinder block and the lower crankcase are flush or do not exceed the following tolerances:
- M/T transaxle: 0.10 mm overlap to 0.25 mm gap.
- CD4E transaxle: 0.00 mm overlap to 0.25 mm gap.





21. Install lower crankcase spacer shims as required.
- 0.26 to 0.50 rum gap, use 0.25 mm (yellow) spacer shims
- 0.51 to 0.75 mm gap, use 0.50 mm (black) spacer shims





22. Tighten the lower crankcase bolts and install the oil intake tube.
1 Tighten the bolts and check the alignment. Correct as necessary.
2 Install the oil intake tube.

NOTE: Install the oil pan within 10 minutes of applying the sealer.





23. Apply a 3 mm bead of Silicone Gasket and Sealant F6AZ-19562-AA meeting Ford specification WSE-M4G323-A6, or equivalent to the mating face of the oil pan.





24. Install the oil pan.
- Tighten the bolts in the indicated sequence.

NOTE:
- Use new flywheel/drive plate bolts.
- Remove any traces of thread-lock compound from the threaded bores.





25. Install the flywheel/drive plate.

NOTE: Do not allow the Spline Grease to contaminate the clutch friction material.

26. Lubricate the clutch disk splines with Spline Grease F5RZ-1950-MA meeting Ford specification ESD-M1C220-A, or equivalent, if equipped.





27. On manual transaxle equipped vehicles, install the clutch.
1 Locate pressure plate and clutch disc on the flywheel.
2 Install the bolts finger tight to center the clutch then tighten to specification.
3 Check that the clutch disk is properly centered.

- Tighten the bolts in a diagonal pattern.





28. Install the cylinder head.
1 Position a new cylinder head gasket on the cylinder block.
2 Install the guide pins.
3 Install the guide sleeves.

CAUTION: The cylinder head bolts must not be torqued more then once.





29. Install the cylinder head bolts.
- Install new, non-oiled cylinder head bolts.
- Tighten the cylinder head bolts in three stages:
- Stage one: 25 Nm
- Stage two: 45 Nm
- Stage three: 105 degree






30. Install a new gasket into the oil feed flange.
- Press the positioning pins on the gasket into the holes.






31. Assemble the exhaust camshaft for installation.
1 Insert the oil feed ring into the oil feed flange.
2 Slide both components together onto the exhaust camshaft.





32. Thinly coat camshaft bearing cap no. 5 with Silicon Gasket and Sealant F6AZ-19562-AA meeting Ford Specification WSE-M4G323-A6, or equivalent.
- Apply the sealant to the indicated areas.






33. Position the oil feed flange.
1 The oil feed flange points upward during installation of the exhaust camshaft.
2 The oil feed ring hole is right at the top.
3 After turning the oil feed flange, the location lug must be in installation position on the cylinder head.

NOTE: The numbering is on the outside of the camshaft bearing caps.





34. Install the camshaft and the camshaft bearing caps to their original position.

NOTE: Do not damage the oil feed flange gasket.





35. Install the camshaft bearing cap bolts in the sequence shown.
- Lubricate the valve tappets with SAE 90 Premium Rear Axle Lubricant XY-90-KL-QL or equivalent meeting Ford specification ESP-M2C154-A, and insert them.
- Lubricate the camshaft bearings with SAE 90 Premium Rear Axle Lubricant XY-9-KL-QL or equivalent meeting Ford specification ESP-M2C154-A.
- Install new oil seals, lubricated with engine oil, on the front of the camshaft.

CAUTION: Record the measured valve clearance for each valve.





36. Measure the valve clearances with feeler gauge.
- Specified valve clearance: intake (0.11 - 0.18 mm).
- Specified valve clearance: exhaust (0.27 - 0.34 mm).

37. If necessary, remove the camshaft(s) to adjust the valve clearance.

NOTE:
- A mid-range valve clearance is optimal (intake 0.15 mm, exhaust 0.30 mm).
- The number on the shim corresponds to the shim thickness. Example: 222 = 2.22 mm.






38. If necessary, measure the required shim thickness to adjust the valve clearance.
- Remove the adjusting shim from the tappets and read off the size from the back (if it is not legible measure it with a micrometer).
- Measure and insert the shim of the required thickness.
- Intake valves: required shim thickness = fitted shim thickness + measured valve clearance -0.15 mm.
- Exhaust valves: required shim thickness = fitted shim thickness + measured valve clearance - 0.30 mm.






39. Reinstall the camshafts and bearing cap bolts in sequence.

NOTE: Keep the oil feed flange gasket away from the cylinder head when turning the flange.





40. Install the oil feed flange bolts.
- Turn the oil feed flange into installation position.

1 Tighten the right-hand bolt.
2 Tighten the left-hand bolt.

NOTE: Rotate the oil feed ring so the single hole is positioned straight up.






41. Check that the oil feed ring moves freely.
- If it is difficult to turn the oil feed ring, loosen the bolts on the oil feed flange and re-tighten them to specification.






42. Set the crankshaft to TDC on cylinder number 1.
- Align the crankshaft pulley notch and indicator.

NOTE: Cylinders 1 and 4 are at TDC when the crankshaft woodruff key points straight up.






43. Remove the blanking plug and install the TDC Timing Peg to hold the crankshaft in position.






44. Install the Camshaft Alignment Timing Tool.
1 Using an open-ended wrench, turn the camshafts by the hexagon in the normal direction of rotation.
2 Slide the Camshaft Alignment Timing Tool into the ends of both camshafts.

NOTE: If the lug is not centered between the two oil bores and the mark, reinstall the exhaust camshaft timing pulley.






45. Install the exhaust camshaft timing pulley.
1 The lug is centered between the oil bores and the mark.
2 The lug must locate in the bore.

NOTE: Install the bolts but do not tighten them. It must be possible to turn the timing pulleys on the camshafts.

46. Slide the timing pulleys onto the camshafts and loosely install the bolts.





47. Install a new gasket in the coolant pump.
1 Position the gasket in the coolant pump.
2 Secure the gasket by bending the tabs over.





48. Install a new timing belt.
1 Position the crankshaft timing pulley and the thrust washer onto the crankshaft.
2 Position the coolant pump and install the bolts.
3 Position the lower idler pulley and install the bolt.
4 Position the upper idler pulley and install the bolt.
6 Starting from the crankshaft pulley and working counter-clockwise, lay the timing belt in place while keeping it under tension.
6 Position the timing belt tensioner and screw the bolt in five turns.

CAUTION:
- Only tension the timing belt tensioner by turning it counter-clockwise.
- Improper timing belt tension will cause improper valve timing.





49. Apply tension to the timing belt.
1 Hook the lug into the sheet metal cover.
2 Tension the belt by turning the timing belt tensioner counter-clockwise until the pointer and the mark are lined up, and then tighten the bolt.

NOTE: Hold the camshaft by the hexagon with an open-ended wrench to stop it from turning.





50. Install the camshaft timing pulleys.
1 Install the camshaft timing pulleys.
2 Install the exhaust camshaft bolt.
3 Remove the aligning tool from the camshafts.





51. Remove Crankshaft TDC Timing Peg and install the blanking plug into the cylinder block.

NOTE: Use a new blanking plug.





52. Position a new O-ring and install a new blanking plug in the exhaust camshaft pulley.

NOTE: Use a new valve cover gasket and a new solenoid valve oil seal.





53. Install the valve cover.
1 Position the cover and install the ten bolts.
2 Connect the spark plug wires to the spark plugs.
3 Position the cylinder head cover plate and install the bolts.

NOTE: Check the seating of the gasket and adjust it if necessary.





54. Install the timing belt covers.
1 Position the lower timing belt cover and install the bolts.
2 Install the crankshaft vibration damper and install the bolt.
3 Position the upper timing belt cover and install the bolts.
4 Position the center timing belt cover/engine mounting bracket and install the bolts.
5 Position the drive belt idler pulley and install the bolt.
6 Position the coolant pump pulley and install the bolts.





55. Position a new gasket and install the oil separator.
1 Install the three separator bolts.
2 Connect the crankcase ventilation tube to the engine block.





56. Install the components on the exhaust side of the engine.
1 Install the air conditioning compressor bracket and bolts.
2 Install the power steering pump bracket to cylinder head bolts.
3 Install the power steering pump bracket to cylinder block bolts.
4 Connect the coolant hose to the thermostat housing and coolant pump.
5 Install the catalytic converter bracket.

57. Attach the engine to the workshop hoist by the engine lifting eyes and remove it from the assembly stand.
- Leave the engine attached to the workshop hoist and rest the engine on the assembly stand.






58. Install the oil filter adapter.





59. Install the components on the intake side of the engine.
1 Position the catalytic converter into the exhaust manifold and install the exhaust manifold bracket and bolts.
2 Install the oil pressure switch.
3 Install the knock sensor (KS).
4 Install a new oil filter. Coat the oil filter seal with Super Premium SAE SW30 Motor Oil XO-SW30-BSP, DSP, QSP meeting Ford specification ESE-M2C153-E or equivalent before assembly.
5 Install the generator bracket bolts.
6 Install the generator bracket nuts.

60. Position the exhaust manifold and install the bolts.





61. Position the catalytic converter and install the nuts.





62. Install the catalytic converter bracket bolt.





63. Install the heat shield.
- Unhook the engine lifting eye from the workshop hoist and remove.
- Install the oil level indicator tube.
- Position the lifting eye.
- Position the heat shield and install the bolts.
- Hook the lifting eye back into the workshop hoist.





64. Install the intake manifold.
1 Install the seven bolts and two nuts.
2 Connect the solenoid valve electrical connector and press in the rubber seal.





65. Install the generator.
1 Install the bolts.
2 Connect the generator electrical connectors.






66. Connect the oil pressure switch electrical connector and the KS electrical connector.





67. Connect the electrical connectors to the CMP sensor and the ECT sensor.
- Clip the CMP and ECT sensor wiring to the EI coil.