Part 1 of 2

Special Tools:

General Equipment:

Materials:

1. CAUTION: Use only plastic scraper when removing old gasket material.

Clean all the mating faces and reusable parts thoroughly and check for damage.

2. NOTE: Never remove pipe plugs or alignment dowels unless they are to be serviced.

Reseal oil passage blanking plugs, as necessary.
^ Use Sealer or equivalent meeting Ford specification WSK-M2G349-A7.

3. NOTE: The main bearings are precision selective fit.

Install the upper crankshaft beatings and thrust washer into the cylinder block.
1 Install the upper crankshaft thrust washer.
2 Install the upper crankshaft main bearings.
^ Lubricate the bearings and thrust washer. Use Assembly fluid or equivalent meeting Ford specification WSF-M2C908-A.

4. CAUTION: Avoid damage to any crankshaft journal hearing surfaces.

Install the crankshaft.

5. NOTE: Force the crankshaft rearward prior to installation of upper thrust bearings.

NOTE: Visually inspect the bearings to verify that the bearing oiling holes align with cylinder block oil feed holes

NOTE: Align assembly tab on thrust bearing to machining spot face on cylinder block.

Install the lower crankshaft bearings into the cylinder block.
1 Install the lower crankshaft thrust main bearing into lower cylinder block.
2 Install the lower crankshaft main bearings into lower cylinder block.
^ Lubricate the bearings and thrust washer. Use Assembly fluid or equivalent meeting Ford specification WSE-M2C908-A.

6. NOTE: Sealant application must stop 6 mm from the rear crankshaft bore on each side.

NOTE: Install lower cylinder block and tighten all bolts to specification within four minutes of applying sealer.

Apply a bead of sealant to the cylinder block housing.
^ Use Black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6.
^ Apply a 3 mm bead to area shown.
^ Apply a 1 mm bead to area shown.

7. CAUTION: Be sure all dowels are fully seated into lower cylinder block prior to torquing bolts.

NOTE: Tighten the bolts in the indicated sequence.

NOTE: Do not lubricate lower cylinder block bolts.

NOTE: Do not rotate crankshaft until all bolts are tightened to specification.

NOTE: Before installing the fasteners use a remover or similar tool to lightly seat the crankshaft forward.

NOTE: Bolts must be tightened within 4 minutes of applying sealant.

Install the bulkhead housing on the cylinder block.
^ Push crankshaft rearward to seat the crankshaft thrust washer.

8. CAUTION: Bolts 1 through 16 are tighten-to-yield and must be replaced.

NOTE: Tighten the bolts in the indicated sequence in four stages.

Complete the tightening sequence.
^ Stage 1: Bolts 1-8, 25 Nm
^ Stage 2: Bolts 9-16, 40 Nm
^ Stage 3: Bolts ]- 16, 90 degrees
^ 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.

10. CAUTION: Use appropriate protection to prevent damage to the crankshaft bearing journals and cylinder bore surface.

Position the crankshaft with journal at bottom of stroke.

11. NOTE: Install pistons with arrow to front of engine.

Compress the rings and install the piston and connecting rod.
^ Lubricate all piston components. Use Assembly fluid or equivalent meeting Ford specification WSE-M2C908-A.

12. 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.

CAUTION: Connecting rod bolts are torqued to yield and must be replaced.

NOTE: Tighten the bolts in the indicated sequence in three stages.

Position the connecting rod cap on the appropriate connecting rod.
^ Stage: 23 Nm
^ Stage 2: 43 Nm
^ Stage 3: 90 degrees

13. Check the connecting rod side clearance.

14. Rotate the crankshaft to ensure proper operation.

15. NOTE: Tighten the bolts in the indicated sequence.

Install the oil pump.

16. NOTE: Oil pan baffle nuts are tightened to yield and must not be reused.

Position the oil pan baffle and install the nuts in two stages.
^ Stage 1: 5 Nm
^ Stage 2: 45° (one-eighth turn)

17. NOTE: Lubricate a new O-ring seal before installation.

Position the oil intake tube and install the bracket nut in two stages.
^ Lubricate new O-ring seal with Ford super premium engine oil SAE 5W-30
^ Stage 1: 5 Nm
^ Stage 2: 45 degrees

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.

21. CAUTION: Cylinder head bolts are installed and tightened in two phases.

NOTE: Tighten the bolts in the indicated sequence in two stages.

NOTE: LH shown, RH similar.

NOTE: LH and RH cylinder head gaskets are not interchangeable.

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.
^ Stage 1: 40 Nm
^ Stage 2: 90 degrees

22. NOTE: RH shown, LH similar.

NOTE: Loosen the bolts in the indicated sequence one full turn (360 degrees).

Loosen the bolts.

23. NOTE: Tighten the bolts in the indicated sequence in three stages.

NOTE: LH shown, RH similar.

Tighten the bolts.
^ Stage: 40 Nm
^ Stage 2: 90 degrees
^ Stage 3: 90 degrees

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.

27. NOTE: LH shown, RH similar.

Install the hydraulic lash adjusters.
^ Lubricate the hydraulic lash adjusters with Engine assembly lubricant prior to installation.

28. Install the LH camshafts.
^ Lubricate the hydraulic lash adjusters with Engine assembly lubricant prior to installation.
^ Align the RFF timing flags on the rear of the sprockets.

29. CAUTION: Do not install thrust caps 1L and 5L at this time, or damage to the thrust caps may occur.

Install the LH camshaft caps in their original positions.
^ Loosely install the camshaft cap bolts.

30. Install the RH camshafts.
^ Lubricate the hydraulic lash adjusters with Engine assembly lubricant prior to installation.
^ Align RFF timing flags on the rear the sprockets.

31. CAUTION: Do not install thrust caps 5R and 1R at this time or damage to the thrust caps may result.

Install the RH camshaft caps in their original positions.
^ Loosely install bolts.

32. Remove the crankshaft pulley bolt, while maintaining the 11 o'clock crankshaft keyway position.

33. NOTE: The colored links of the timing chain and the marks on the timing sprockets must line up.

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 vise with Jaw protectors.

35. 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.

Hold the LH timing chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

36. NOTE: Piston should retract with minimal force. If binding occurs, reposition tensioner to eliminate side loading.

Slowly compress the timing chain tensioner.

37. NOTE: Wire must remain in the timing chain tensioner until the tensioner is installed into the engine with the piston bottomed in the bore.

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 tensioner adapter plate LH, the timing chain tensioner and bolts.

39. NOTE: The colored links of the timing chain and the marks on the sprocket must line up.

Install the RH timing chain.
1 Install 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 vise with jaw protectors.

41. 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.

Hold the RH timing chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

42. NOTE: Piston should retract with minimal force. If binding occurs, reposition tensioner to eliminate side loading.

Slowly compress the RH timing chain tensioner.

43. NOTE: Wire must remain in the timing chain tensioner until the tensioner is installed with the piston bottomed in the bore.

Retain piston with a 1.5 mm wire or paper clip.

44. Install the RH timing chain tensioner.
1 Install the tensioner arm (tan material).
2 Install the tensioner adapter plate RH, the timing chain tensioner and bolts.

45. CAUTION: Crankshaft keyway must be in the 11 o'clock position prior to installation of the LH cylinder head roller ringer followers.

NOTE: Verify that all timing marks and reference flags are in the correct position before installing the roller finger followers.

NOTE: Roller finger followers must be installed in their original positions.

Install the LH roller finger followers.
^ Lubricate the roller finger followers with Engine assembly lubricant prior to installation.

46. 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.

NOTE: Tighten the bolts in the indicated sequence in several phases.

Tighten the bolts.
^ With LH cylinder head roller finger followers installed, align camshaft end play using thrust caps as a guide prior to tightening journal caps.

47. Install the crankshaft pulley bolt and washer.

48. CAUTION: Rotating the crankshaft counterclockwise may cause the timing chains to bind and may cause engine damage.

Rotate the engine clockwise to locate the crankshaft keyway to the 3 o'clock position.
^ Reinstall the crankshaft pulley bolt and washer.

49. 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.

Install the RH roller finger followers.
^ Lubricate the roller finger followers with Engine assembly lubricant prior to installation.

50. 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.

NOTE: Tighten the bolts in the indicated sequence in several passes.

Tighten the bolts.
^ With RH cylinder head roller finger followers installed, align camshaft end play using thrust caps as a guide prior to tightening journal caps.

51. NOTE: LH shown, RH similar.

Remove the RH and LH chain tensioner retaining wires.

52. Remove the crankshaft pulley bolt and washer.

53. NOTE: Install the engine front cover within six minutes after applying the sealant.

Install the crankshaft position sensor pulse wheel and apply a 6 mm dot of sealant to the mating faces.
^ Install the rotor with the indentation towards the front.

1 Use the keyway marked 2.5L (blue paint stripe).
^ Clean the front cover to cylinder block and cylinder head sealing surfaces with Metal surface cleaner.
^ Use Black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6.

2 Apply sealer.

54. NOTE: The engine front cover must be installed in a two-step sequence.

Install the engine front cover.
^ Install new gaskets in the engine front cover.
^ Note locating dowels and the locations of the studs.
^ Tighten the bolts and studs one-quarter turn (90 degrees) in the indicated sequence after engine front cover contacts cylinder block and cylinder heads.

55. NOTE: Tighten the bolts and struts in the indicated sequence.

Install the remaining engine front cover.

56. Install the sensors and wiring brackets.
^ Lubricate the new O-ring seals with Ford super premium engine oil SAE 5W-30 before installation.
^ Install the CKP sensor and bolt.
^ Install the CMP sensor and bolt.

57. Using the special tools, install the crankshaft front oil seal.
^ Lubricate the outer ring and sealing- lip with Ford super premium engine oil SAE 5W-30before installation.

58. Apply Black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6 to the front of the crankshaft on the inside diameter surface of the crankshaft pulley at keyway.
^ Prior to applying sealer, clean sealing surfaces with Metal surface cleaner or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealers ability to adhere.

59. NOTE: Use the crankshaft pulley bolt washer for installation.

Using the special tool, install the crankshaft pulley.

60. Install the crankshaft pulley.
^ Use Black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6 and seal the keyway in the pulley.

1 Use a Suitable strap wrench to hold the crankshaft pulley.
2 Tighten the crankshaft pulley bolt in four stages.
^ Stage 1: 120 Nm
^ Stage 2: Back off bolt one full turn
^ Stage 3: 50 Nm
^ Stage 4: 90 degrees

61. Install the power steering pump and bracket.
^ Loosely install all bolts and studs.

62. NOTE: The longer 84 mm bolts should be tightened first.

Tighten the bolts.

63. Tighten the stud nuts.

64. CAUTION: Tightening pulley with dimple facing power steering pump will bend the pulley.

NOTE: The dimple on pulley must face toward the front of the engine.

Install the power steering pump belt pulley.

65. Install the camshaft oil seal retainer.

^ Install a new gasket and align the retainer on the locating dowels.

66. CAUTION: The running surface of the camshaft must not be damaged.

Using the special tools, install the camshaft oil seal.
^ Lubricate the camshaft oil seal with Ford super premium engine oil SAE 5W-30.

1 Install special tool.
2 Position a new seal and the special tool.
3 Install special tool and install the seal.