Part 1

Engine

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)














Material(s)






Exploded View

Intake Manifold and Valve Train Exploded View













Rear Engine Components Exploded View









Timing Drive and Lower Engine Components Exploded View














Assembly

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. REFER to Engine System - General Information.

1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.

NOTE: The front bulkhead does not have an engine piston oil cooler.
Install the 4 engine piston oil coolers.
- Tighten to 4 Nm (35 lb-in).





2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.





3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.





4. Tighten the 10 original main bearing beam bolts in the sequence shown in 3 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
- Stage 3: Tighten an additional 90 degrees.





5. Measure each crankshaft block main bearing bore diameter.





6. Using the chart, select the crankshaft main bearings.





7. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 2 stages:
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.





8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.

- Remove the bolts and the connecting rod cap.
- Discard the connecting rod cap bolts.






9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.





10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.





11. Remove the 10 bolts in the sequence shown and the main bearing beam.

- Discard the main bearing beam bolts.






12. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

NOTE: The center bulkhead is the thrust bearing.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.





13. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.





14. NOTE: Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.





15. Lubricate the 10 main bearing beam side fit surfaces and the 5 main bearing beam bearings with clean engine oil.





16. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.





17. NOTE: Lubricate the main bearing beam bolt threads and under the bolt heads with clean engine oil.

NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts
Install and tighten the 10 new main bearing beam bolts in the sequence shown in 3 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
- Stage 3: Tighten an additional 90 degrees.





18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.

- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- Acceptable crankshaft end play is 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.






19. Piston to be assembled with the arrow pointing to the front of the engine.





20. Connecting rod to be assembled with the front marks pointing to the front of the engine.





21. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
Using the 303-D032 (D81L-6002-C) and the 303-462 (T94P-6136-AH) , install the piston and connecting rod assemblies.

- When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
- The position of the upper and lower compression ring gaps are not controlled for installation.






22. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.

NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
Install the connecting rod caps and the new bolts and tighten the bolts in 2 stages:
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.





23. Install the 303-507 and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the 303-507. The engine is now at TDC (Top Dead Center).





24. NOTE: Clean the oil pump and cylinder block mating surfaces with Motorcraft(R) Metal Surface Prep.
Install the oil pump assembly.
- Tighten the 4 bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).





25. Install the oil pump sprocket and bolt.
- Tighten to 25 Nm (18 lb-ft).





26. Install the diamond washer and the crankshaft sprocket.






27. Install the chain on the oil pump sprocket.

1. Install the tensioner and the 2 shoulder bolts.
- Tighten to 10 Nm (89 lb-in).

2. Push the tensioner spring down and position the spring under the shoulder bolt.





28. Using the 303-328 (T88P-6701-B1) , position the crankshaft rear oil seal with retainer plate onto the crankshaft.
- Install the 6 bolts and tighten in the sequence shown to 10 Nm (89 lb-in).
- Remove the 303-328 (T88P-6701-B1).





29. Using a new gasket, install the oil pump screen and pickup tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





30. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the oil pan-to-engine block mating surface.





31. Position the oil pan onto the engine and install the 12 oil pan bolts finger-tight.





32. Using a straight edge, align the front surface of the oil pan flush with the front surface of the engine block.






33. Tighten the 12 oil pan bolts in the sequence shown.
- Tighten to 20 Nm (177 lb-in).





34. Install the 2 cylinder head alignment dowels.