Part 1 of 2
ASSEMBLYCAUTION: Use only plastic scraper when removing old gasket material.
1. Clean all the mating faces and reusable parts thoroughly and check for damage.
NOTE: Never remove pipe plugs or alignment dowels unless they are to be serviced.
2. Reseal oil passage blanking plugs, as necessary.
- Use Sealer meeting Ford specification WSK-M2G349-A7.
NOTE: The main bearings are precision selective fit.
3. Install the upper crankshaft bearings and thrust washer into the cylinder block.
1 Install the upper crankshaft thrust washer.
2 Install the upper crankshaft main bearings.
3 Lubricate the bearings and thrust washer. Use API, SO SAE 50 Assembly Fluid or equivalent meeting Ford specification WSE-M2C908-A.
CAUTION: Avoid damage to any crankshaft journal bearing surfaces.
4. Install the crankshaft.
NOTE:
- Force the crankshaft rearward prior to installation of upper thrust bearings.
- Visually inspect the bearings to verify that the bearing oiling holes align with cylinder block oil feed holes.
- Align assembly tab on thrust bearing to machining spot face on cylinder block.
5. Install the lower crankshaft bearings into the cylinder block.
1 Install the lower crankshaft thrust main bearing onto lower cylinder block.
2 Install the lower crankshaft main bearings onto lower cylinder block.
3 Lubricate the bearings and thrust washer. Use API, SO SAE 50 Assembly Fluid or equivalent meeting Ford specification WSE-M2C908-A.
NOTE:
- Sealant application must stop 6 mm from the rear crankshaft bore on each side.
- Install lower cylinder block and torque all bolts to specification within four minutes of applying sealer.
6. Apply a bead of sealant to the cylinder block housing.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
- Apply a 3mm bead to area shown.
- Apply a 1 mm bead to area shown.
CAUTION: Be sure all dowels are fully seated into lower cylinder block prior to torquing bolts.
NOTE:
- Do not lubricate lower cylinder block bolts.
- Do not rotate crankshaft until all bolts are torqued to specification.
- Before installing the fasteners use a prybar or similar tool to lightly seat the crankshaft forward.
NOTE: Bolts must be tightened within 4 minutes of applying sealant.
7. Position the bulkhead housing on the cylinder block and tighten fasteners in the indicated sequence.
- Push crankshaft rearward to seat the crankshaft thrust washer.
CAUTION: Bolts 1 through 16 are torque-to-yield and must be replaced.
8. Complete tightening sequence in four stages as indicated.
- Stage 1: Bolts 1-8, 25 Nm
- Stage 2: Bolts 9-16, 40 Nm
- Stage 3: Bolts 1-16, 90°
- Stage 4: Bolts 17-22, 25 Nm
- Verify the crankshaft rotates freely.
9. Remove excess sealant which may squeeze out at the front cover sealing surface.
CAUTION: Use appropriate protection to prevent damage to the crankshaft bearing journals and cylinder bore surface
10. Position the crankshaft with journal at bottom of stroke.
NOTE: Install pistons with arrow to front of engine.
11. Compress the rings and install the piston and connecting rod.
- Lubricate all piston components. Use API, SO SAE 50 ASSEMBLY Fluid or equivalent meeting Ford specification WSE-M2C908-A.
CAUTION:
- When assembling the connecting rods and connecting rod caps, it is imperative that bearing slots and tangs be located on the same side of the connecting rods.
- Connecting rod bolts are torqued to yield and must be replaced.
12. Position the connecting rod cap on the appropriate connecting rod and alternately tighten the bolts in three stages as indicated.
- Stage 1: 23 Nm
- Stage 2: 43 Nm
- Stage 3: 90°
13. Check the connecting rod side clearance.
14. Rotate the crankshaft to ensure proper operation.
15. Install the oil pump.
- Tighten the bolts in the indicated tightening sequence.
NOTE: Oil pan Same nuts are torqued to yield and must not be reused.
16. Position the oil pan baffle and install the nuts in two stages.
- Stage 1: 5Nm
- Stage 2: 45° (one-eighth turn)
NOTE: Lubricate a new O-ring with light engine oil before installation.
17. Position the oil intake tube and install the bracket nut in two stages.
- Stage 1: 5 Nm
- Stage 2: 45°
18. Install the oil intake tube bolts.
19. Install the oil separator.
- Install a new gasket with the guide(s) facing the cylinder block.
20. Install the power steering pump bracket.
- Align the bracket with the locating sleeves.
CAUTION: Cylinder head bolts are installed and tightened in two phases.
NOTE: LH shown, RH similar.
NOTE: LH and RH cylinder head gaskets are not interchangeable.
21. Install the cylinder heads.
- Install a new cylinder head gasket and align the cylinder head with the locating sleeves.
- Insert new cylinder head bolts with washers..
- Tighten the cylinder head bolts in the indicated tightening sequence in two stages.
- Stage 1: 40 Nm
- Stage 2: 90°
NOTE: RH shown, LH similar.
22. Loosen the cylinder head bolts in the sequence shown.
- Loosen the bolts one full turn (360°).
NOTE: LH shown, RH similar.
23. Tighten the cylinder head bolts in the indicated sequence in three stages.
- Stage 1: 40 Nm
- Stage 2: 90°
- Stage 3: 90°
24. Verify all camshaft specifications.
25. Install the crankshaft pulley washer and bolt.
26. Position the crankshaft.
- Turn the key clockwise to the 11 o'clock position.
NOTE:
- Lubricate the hydraulic lash adjusters with engine assembly lubricant D9AZ-19579-D prior to installation.
- LH shown, RH similar.
27. Install the hydraulic lash adjusters.
NOTE: Lubricate the camshafts with engine assembly lubricant D92AZ-19579-D.
28. Install the LH camshafts.
- Align the camshaft sprockets. Testing and Inspection
CAUTION: Do not install thrust caps IL and 5L at this time, or damage to the thrust caps may occur.
29. Install the LH camshaft caps in their original positions.
- Loosely install the camshaft cap bolts.
NOTE: Lubricate the camshafts with engine assembly lubricant D9AZ-19579-D.
30. Install the RH camshafts.
- Align the camshaft sprockets. Testing and Inspection
CAUTION: Do not install thrust caps 5R and 1R at this time or damage to the thrust caps may result.
31. Install the RH camshaft caps in their original positions.
- Loosely install the camshaft cap bolts.
32. Remove the crankshaft pulley bolt, while maintaining the 11 o'clock crankshaft keyway position.
NOTE: The colored links of the timing chain and the marks on the timing sprockets must line up.
33. Install the LH timing chain.
1 Install the LH chain guide and bolts (black material).
2 Install the crankshaft sprocket.
3 Install the timing chain.
34. Position the LH timing chain tensioner in a softjawed vise.
CAUTION: During tensioner compression, do not release ratchet stem until tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
35. Hold the LH timing chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
NOTE: Piston should retract with minimal force. If binding occurs, reposition tensioner to eliminate side loading.
36. Slowly compress the timing chain tensioner.
NOTE: Wire must remain in the timing chain tensioner until the tensioner is installed into the engine with the piston bottomed in the bore.
37. Retain piston with a 1.5 mm wire or paper clip.
38. Install the LH timing chain tensioner.
1 Install the LH tensioner arm (black material).
2 Install the timing chain tensioner and bolts.
NOTE: The colored links of the timing chain and the marks on the sprocket must line up
39. Install the RH timing chain.
1 In stall the tensioner arm and bolts (tan material)
2 Install the crankshaft sprocket.
3 Install the timing chain.
40. Position the RH timing chain tensioner in a softjawed vise.
CAUTION: During tensioner compression, do not release ratchet stem until tensioner piston is fully bottomed in its bore, or damage to the ratchet stem will result.
41. Hold the RH timing chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
NOTE: Piston should retract with minimal force. If binding occurs, reposition tensioner to eliminate side loading.
42. Slowly compress the RH timing chain tensioner.
NOTE: Wire must remain in the timing chain tensioner until the tensioner is installed with the piston bottomed in the bore.
43. Retain piston with a 1.5 mm wire or paperclip.
44. Install the RH timing chain tensioner.
1 Install the tensioner arm (tan material).
2 Install the timing chain tensioner and bolts.
CAUTION: Crankshaft keyway must be in the 11 o'clock position prior to installation of the LH cylinder head roller finger followers.
NOTE:
- Verify that all timing marks are in the correct position before installing the roller finger followers.
- Roller finger followers must be installed in their original positions.
- Lubricate the roller finger followers with engine assembly lubricant D9AZ-19579-D.
45. Install the LH roller finger followers.
CAUTION: Do not install the LH cylinder head camshaft journal thrust caps until camshaft journal caps are installed or damage to the thrust caps may occur.
46. Tighten the LH camshaft cap bolts in the indicated sequence in several passes.
- With LH cylinder head roller finger followers installed, align camshaft end play using thrust caps as a guide prior to torquing journal caps.
47. Install the crankshaft pulley bolt and washer.
CAUTION: Rotating the crankshaft counter clockwise may cause the timing chains to bind and may cause engine damage.
48. Rotate the engine clockwise to locate the crankshaft keyway to the 3 o'clock position.
- Re-install the crankshaft pulley bolt and washer.
CAUTION: Crankshaft key must be in the 3 o'clock position prior to installation of the RH cylinder head roller finger followers.
NOTE:
- Roller finger followers must be installed in their original position.
- Lubricate the roller finger followers with engine assembly lubricant D9AZ-19579-D
49. Install the RH roller finger followers.
CAUTION: Do not install RH cylinder head camshaft journal thrust caps until camshaft journal caps are installed, or damage to the thrust caps may occur.
50. Tighten the RH camshaft cap bolts in the indicated sequence in several passes.
- With RH cylinder head roller finger followers installed, align camshaft end play using thrust caps as a guide prior to torquing journal caps.
NOTE: LH shown, RH similar.
51. Remove the RH and LH chain tensioner retaining wires.
52. Remove the crankshaft pulley bolt and washer.
53. Install the crankshaft position sensor pulse wheel.
- Install the rotor with the indentation towards the front.
- Use the keyway marked 2.5L (blue paint stripe).
NOTE: Install the engine front cover within six minutes after applying the sealant.
54. Apply a 6 mm dot of sealant to the mating faces.
- Clean the front cover to cylinder block and cylinder head sealing surfaces with metal surface cleaner F4AZ- 1 9A536-RA.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
NOTE: The engine front cover must be installed in a two-step sequence.
55. Install the engine front cover.
- Install new gaskets in the engine front cover.
- Note locating dowels and the locations of the studs.
- Install the bolts and studs in the indicated sequence and tighten in two steps.
- First tighten the bolts and studs one-quarter turn (90�) after engine front cover contacts cylinder block and cylinder heads