Crankshaft: Service and Repair

Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in the timing belt service and repair procedure. Timing Belt


REMOVAL
1. Install engine on Rotunda Engine Stand 164-R3503 or equivalent, following manufacturer's instructions using Rotunda Power Floor Crane 014-00071 or equivalent.
2. Loosen four bolts retaining water pump pulley (8509) to water pump (8501) (Do NOT remove bolts).
3. Release front end accessory drive belt tension by rotating drive belt tensioner (6B209) clockwise.
4. Remove drive belt (8620).
5. Disconnect ignition wires from spark plugs (12405).
6. Remove oil level dipstick (6750).
7. Loosen water pump to lower radiator hose spring clamp. Remove lower radiator hose from water pump.
8. Remove upper camshaft timing belt cover retaining bolts and upper camshaft timing belt cover.
9. Loosen valve cover retainer bolts in a standard-type removal sequence. Remove valve cover (65823 from cylinder head (6049).
10. Remove spark plugs from cylinder heads.
11. Remove water pump pulley retaining bolts and water pump pulley from water pump.





12. Rotate crankshaft to top dead center (TDC) No. 1 cylinder. This will position all pistons below top of cylinder block deck face.
13. Remove crankshaft pulley retainer bolt from crankshaft (6303).
14. Remove crankshaft pulley (6312) from crankshaft.
15. Remove oil bypass filter (6714).
16. Remove oil pan drain plug and drain engine oil. Reinstall oil pan drain plug. Tighten to 21-28 Nm (15-21 ft. lbs.).

CAUTION: To prevent residue in bottom of oil pan (6675) from entering engine, remove oil pan prior to turning engine upside down on engine stand.

17. In a standard-type removal sequence, remove oil pan retaining bolts.
18. Remove oil pan and oil pan gasket (6710) from cylinder block (6010).
19. Remove center and lower camshaft timing belt covers from front of engine.
20. Loosen camshaft timing belt tensioner pulley retaining bolt and move camshaft timing belt tensioner pulley away from camshaft timing belt.
21. Mark direction of rotation of camshaft timing belt and remove camshaft timing belt.
22. Remove camshaft timing belt tensioner pulley retaining bolt and camshaft timing belt tensioner pulley from front of engine. Discard pulley retaining bolt.
23. Remove crankshaft sprocket (6306) and camshaft timing belt guide from crankshaft.
24. Turn engine over on engine stand.
25. Remove oil pump screen cover and tube support self-locking retaining nut and discard nut.





26. Remove oil pump screen cover and tube retaining bolts, oil pump screen cover and tube (6622) and gasket from oil pump (6600).
27. Remove oil pan baffle retaining nuts and oil pan baffle (6687) from cylinder block main bearing cap retaining stud bolts.

CAUTION: Avoid scratching or damaging the oil seal sealing surfaces on the crankshaft and camshaft rear oil seal retainer or possible oil leakage may occur.

28. Using a sharp awl, punch a hole in the crankshaft rear oil seal metal surface, between the crankshaft rear oil seal lip and the crankshaft rear oil seal retainer.





29. Screw in the threaded end of the Jet Plug Remover T77L-9533-B or equivalent into the crankshaft rear oil seal (6701) and remove crankshaft rear oil seal from the crankshaft rear oil seal retainer (6335).
30. Remove retaining bolts for the crankshaft rear oil seal retainer to the cylinder block and remove the crankshaft rear oil seal retainer and crankshaft rear oil seal retainer gasket (6344).
31. Remove oil pump retaining bolts. Remove oil pump from cylinder block. Inspect oil pump.

CAUTION: Connecting rods (6200), connecting rod caps and connecting rod bearings (6211) should be numbered to make sure they are assembled in their original positions.

32. Identify the connecting rods, connecting rod bearings and connecting rod caps for cylinder position.
33. Turn crankshaft until connecting rod cap to be removed is at the high point of its travel.





34. Remove the connecting rod cap and connecting rod bearings. Keep connecting rod cap and connecting rod bearings together. Using Connecting Rod Guides T93P-6136-A inserted into the bottom of connecting rod bolt holes, push the piston (6108) and connecting rod to the top of the cylinder bore. Use care to prevent damage to the crankshaft bearing journals, cylinder bore surfaces and cylinder heads.

CAUTION: Care should be taken not to damage the connecting rod and cap joint face surfaces.

NOTE: Connecting rod bolts are retained in the bolt hole with a light press fit. The bolts have been torqued to yield at-least twice and must be discarded. Use a hammer and punch to drive bolt from bolt hole.





35. Remove used connecting rod bolts from connecting rod caps. Prevent damaging the connecting rod joint face surfaces.
36. Remove retaining bolts for crankshaft main bearing caps to cylinder block.
37. If bearings are to be reused, mark position of lower main bearings.
38. Remove lower main bearings from crankshaft main bearing caps.

CAUTION: When removing crankshaft, use care not to damage any crankshaft journal bearing surfaces.

39. Remove crankshaft.
40. If bearings are to be reused, mark position of upper main bearings and upper crankshaft thrust main bearing (6337).





41. Remove upper main bearings and crankshaft thrust main bearing from cylinder block.
42. If necessary, remove crankshaft key from crankshaft keyway.
43. Clean and inspect cylinder block, crankshaft and connecting rods. Replace cylinder block, crankshaft and connecting rods if required.

INSTALLATION

NOTE: Prior to service reinstallation or replacement of fasteners, all threads and contact surfaces of fasteners must be lubricated with Super Premium Motor Oil X0-5W30-QSP or equivalent meeting Ford specification ESE-M2C153-E unless specified.

1. Clean gasket material, dirt and debris from cylinder block and crankshaft rear oil seal retainer sealing surfaces.

NOTE: Using a hammer, lightly tap crankshaft key into crankshaft keyway.

2. With front of crankshaft supported by wood blocks, install crankshaft key into crankshaft keyway.
3. Install upper crankshaft main bearings (6333) and crankshaft thrust main bearing in cylinder block with the tang fitted in the slot provided.
4. Install the lower crankshaft main bearings in the crankshaft main bearing caps.
5. Carefully lower crankshaft into place. Use care to prevent damage to bearing surfaces.
6. Check clearance of each crankshaft main bearing and crankshaft thrust main bearing.
7. After bearings have been fitted, apply a light coat of Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification ESE-M2C153-E to journals and bearings.

CAUTION: Make sure main bearing caps are installed in their original positions.

8. Install all crankshaft main bearings and crankshaft thrust main bearing and crankshaft main bearing caps. Tighten crankshaft main bearing cap retaining bolts, except for the No. 3 crankshaft thrust main bearing. Tighten retaining bolts to 75-90 Nm (55-66 ft. lbs.).

NOTE: Wedge crankshaft forward to fully seat crankshaft thrust main bearings. Leave pry bar or similar tool in position until the crankshaft thrust main bearing cap retaining bolts are tightened.

9. Push crankshaft forward and pry main thrust bearing cap to the rear. This will align thrust surfaces of both halves of crankshaft thrust main bearing.





10. Tighten the crankshaft thrust main bearing cap retaining bolts to 75-90 Nm (55-66 ft. lbs.).
11. Remove pry bar or similar tool used as wedge from crankshaft and cylinder block.
12. Verify crankshaft rotates freely and does not bind.
13. Check crankshaft end play in both directions using Rotunda Dial Indicator with Bracketry TOOL-4201-C or equivalent.

NOTE: Clearance between cylinder block oil pan sealing surface to crankshaft rear oil seal retainer oil pan sealing surface should not exceed 0.2-0.8 mm (0.012-0.031 inch).





14. Install crankshaft rear oil seal retainer with a new crankshaft rear oil seal retainer gasket to the cylinder block. Align oil pan sealing surfaces using a straight edge. Install and tighten retaining bolts to 18-22 Nm (13-16 ft. lbs.).

NOTE: Lubricate crankshaft flange and crankshaft rear oil seal bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A prior to installation of crankshaft rear oil seal.

Fig. 23 Crankshaft rear oil seal installation:

15. Install crankshaft rear oil seal using Crankshaft Rear Seal Replacer T88P-6701-B1 and a rubber mallet. Seat the crankshaft rear oil seal 0.5-0.0 mm (0.020-0.0 inch) flush to rear of the crankshaft rear oil seal retainer.

NOTE: The connecting rod bearing tangs should align with notch in connecting rod and cap.

16. Install connecting rod bearings into connecting rods and connecting rod caps.

CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Pull piston down until connecting rod bearing seats on crankshaft journal.

17. Turn crankshaft until crankshaft throw is at bottom of stroke. Install correctly numbered connecting rod with Connecting Rod Guides T93P-6136-A until connecting rod seats on crankshaft journal.

CAUTION: It is imperative that the connecting rod cap be properly aligned to the connecting rod. The connecting rod and connecting rod cap bearing tangs must be located on same side of connecting rod.

18. Check clearance of each connecting rod bearing.
19. After connecting rod bearings have been fitted, apply a light coat of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to journals and connecting rod bearing.

CAUTION: Connecting rod bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.

20. Install connecting rod cap and connecting rod bearing onto connecting rod. Alternately tighten new torque-to-yield connecting rod bolts in several passes to 35 Nm (26 ft. lbs.). Rotate connecting rod bolts 85-95°.
21. After installation of each connecting rod assembly, rotate crankshaft to ensure smooth operation.





22. Check connecting rod side clearance using Dial Indicator with Bracketry TOOL-4201-C 014-00282 or equivalent. Side clearance should be 0.090-0.320 mm (0.004-0.013 inch). If connecting rod side clearance is greater than maximum service limit, replace connecting rod and/or crankshaft.
23. Rotate inner rotor of oil pump to align with flats on crankshaft.

NOTE: Clearance between cylinder block oil pan sealing surface to oil pump oil pan sealing surface should not exceed 0.2-0.8 mm (0.012-0.031 inch).





24. Carefully install oil pump onto crankshaft until seated against cylinder block with new gasket. Align oil pump oil pan sealing surface to cylinder block oil pan sealing surface using a straight edge.
25. Install oil pump retaining bolts and tighten in sequence to 8-11.5 Nm (71-102 inch lbs.).
26. If required, replace crankshaft front seal (6700).
27. Install oil pan baffle and retaining nuts. Tighten nuts to 17-21 Nm (13-15 ft. lbs.).
28. Install oil pump screen cover and tube with a new gasket to oil pump. Tighten oil pump screen cover and tube retaining bolts to 8-11 Nm (71-97 inch lbs.).
29. Install new self-locking oil pump screen cover and tube support nut to crankshaft main bearing cap stud bolt. Tighten nut to 17-21 Nm (13-15 ft. lbs.).
30. Clean oil pan to cylinder block sealing surfaces on oil pan and cylinder block with shop towel and Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent.





31. Apply a 3 mm (0.25 inch) bead of Silicone Gasket and Sealant F1AZ-19562-A or equivalent meeting Ford specification WSE-M4G320-A2 to the parting lines of the oil pump and crankshaft rear main seal retainer on cylinder block at oil pan sealing surfaces.
32. Install oil pan gasket, oil pan and oil pan retaining bolts to cylinder block.





33. Align rear surface of oil pan with rear surface of cylinder block using a steel straightedge and tighten oil pan retaining bolts in standard-type torque sequence to 20-24 Nm (15-18 ft. lbs.).
34. Turn engine right side up on engine stand.





35. Install Camshaft Alignment Timing Tool T94P-6256-CH onto the rear of the camshafts (6250).

CAUTION: Crankshaft must be at TDC No. 1 cylinder prior to camshaft timing belt installation. Failure to do so may lead to engine damage.

36. Loosely install crankshaft pulley and rotate crankshaft to TDC, No. 1 cylinder.
37. Install camshaft timing belt guide and crankshaft sprocket onto crankshaft. Align crankshaft key with keyway on crankshaft sprocket.
38. Install camshaft timing belt tensioner pulley to front of engine. Install new retaining bolt finger tight.

CAUTION: Upon first service or replacement of camshaft timing belt, the tensioner spring must be installed onto camshaft timing belt tensioner pulley to obtain the proper tension on camshaft timing belt. Failure to install tensioner spring may cause premature wear or failure of the camshaft timing belt and possible damage to engine.





39. Install retaining bolt and tensioner spring onto camshaft timing belt tensioner pulley and front of engine, if necessary. Tighten retainer bolt to 8-11 Nm (71-97 inch lbs.).

NOTE: Make sure that the crankshaft is at TDC, No.1 Cylinder prior to installation of camshaft timing belt.

40. Position the camshaft timing belt tensioner pulley to allow for installation of the camshaft timing belt Tighten new camshaft timing belt tensioner pulley retaining bolt securely.
41. Install the camshaft timing belt onto the crankshaft sprocket and camshaft sprockets (6256) in a counterclockwise direction.
42. Make sure that the span on the camshaft timing belt from the crankshaft sprocket to the exhaust camshaft is not loose and that the camshaft timing belt is evenly aligned on all sprockets.
43. Install lower timing belt cover and retaining bolts. Tighten bolts to 6-8 Nm (53-71 inch lbs.).

NOTE: Silicone Gasket and Sealant F1AZ-19562-A or equivalent meeting Ford specification WSE-M4G320-A2 must be applied to crankshaft keyway prior to installing crankshaft pulley.

44. Install crankshaft pulley and retaining bolt. Tighten retaining bolt to 110-120 Nm (81-89 ft. lbs.).

NOTE: Make sure that the crankshaft is at TDC, No. 1 Cylinder position.

45. Loosen the camshaft timing belt tensioner pulley retaining bolt and allow the spring attached to the tensioner pulley to pull the tensioner pulley against the camshaft timing belt.
46. Remove the Camshaft Alignment Timing Tool T94P-6256-CH from the camshaft.
47. Turn the crankshaft two revolutions in a clockwise direction.
48. Tighten the camshaft timing belt tensioner pulley retaining bolt to 35-40 Nm (26-30 ft. lbs.).
49. Verify that the crankshaft is at TDC, No.1 cylinder and that the camshafts are aligned using the Camshaft Alignment Timing Tool T94P-6256-CH.

NOTE: If the crankshaft and camshafts are slightly misaligned, the camshafts can be moved using Camshaft Sprocket Holding Tool T74P-6256-B so that the Camshaft Alignment Timing Tool T94P-6256-CH can be installed. The crankshaft MUST remain at TDC, No.1 cylinder.

50. If a camshaft is not properly aligned with the camshaft Timing belt installed, proceed to Step 51. If the crankshaft and camshafts are properly aligned, remove Camshaft Alignment Timing Tool T94P-6256-CH and proceed to Step 55.





51. Loosen the retaining bolt for the camshaft sprocket to the camshaft by holding the camshaft sprocket in position with the Camshaft Sprocket Holding Tool T74P-6256-B.
52. Turn the camshaft until the Camshaft Alignment Timing Tool T94P-6256-CH can be installed.

NOTE: The crankshaft must be in the TDC position of the No. 1 cylinder.

53. While holding the camshaft sprocket in position with the Camshaft Sprocket Holding Tool T74P-6256-B, tighten the retaining bolt for the camshaft sprocket to 64-72 Nm (47-53 ft. lbs.).
54. Remove special tools and turn crankshaft two revolutions in a clockwise direction and verify alignment of the camshafts to the crankshaft.
55. Install center camshaft timing belt cover to front of engine. Tighten retaining bolts to 6-8 Nm (53-71 inch lbs.).

WARNING: EYE PROTECTION IS REQUIRED TO BE WORN DURING USE OF COMPRESSED AIR. FAILURE TO WEAR EYE PROTECTION COULD RESULT IN POSSIBLE PERSONAL INJURY.

56. Clean oil pan with suitable soap and water solution. Dry completely with compressed air.

Part 1 Of 2:

Part 2 Of 2:

57. Install center timing belt cover. Tighten retaining bolts to 6-8 Nm (53-71 inch lbs.).
58. Lubricate oil bypass filter rubber seal with Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification ESE-M2C153-E and install oil bypass filter. Tighten oil bypass filter one-half turn after rubber seal contacts sealing surface.
59. Install water pump pulley and retaining bolts to water pump. Tighten retaining bolts finger tight at this time.

NOTE: Verify and correct, if necessary, spark plug electrode gap to 1.5 mm (0.060 inch) prior to installation.

60. Install spark plugs into cylinder heads. Tighten spark plugs to 13-17 Nm (9-13 ft. lbs.).
61. Using a shop towel and Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent, clean cylinder head-to-valve cover sealing surfaces.

Fig. 13 Valve cover replacement:

62. Install valve cover gasket (6584), valve cover, O-rings, spacers and retaining bolts. Tighten in a standard-type torque sequence to 6-8 Nm (53-71 inch lbs.).
63. Install upper camshaft timing belt cover. Tighten retaining bolts to 3-5 Nm (27-44 inch lbs.).
64. Lubricate lower radiator hose (8286) with Silicone Lubricant D7AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A. Install lower radiator hose onto water pump. Install lower radiator hose to water pump spring clamp securely.
65. Install oil level dipstick.
66. Connect ignition wires to spark plugs. Install ignition wire separators onto valve cover. See Powertrain Management.
67. Rotate accessory drive belt tensioner clockwise and install accessory drive belt. Carefully release drive belt tensioner.
68. Tighten four water pump pulley retaining bolts to 10-14 Nm (89-124 inch lbs.).
69. Remove engine from Rotunda Engine Stand 164-R3503 or equivalent using Rotunda Power Floor Crane 014-00071 or equivalent.