Steps 1 - 58

Special Tools:

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 meeting Ford specification WSK-M2G349-A7.

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





Install the upper crankshaft bearings and thrust washer.
1 Install the thrust washer.
2 Install the main bearings.
- Lubricate the bearings and thrust washer. Use Assembly fluid or equivalent meeting Ford specification WSE-M2C908-A.

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





Install the crankshaft.

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

NOTE: Visually inspect the bearings to check 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 thrust main bearing onto lower cylinder block.
2 Install the main bearings onto 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 torque 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 tightening bolts.

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 lever or similar tool to lightly seat the crankshaft forward.

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





Position the bulkhead housing on the cylinder block and tighten fasteners in the indicated sequence.
- Push crankshaft rearward to seat the crankshaft thrust washer.

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





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 degrees
- Stage 4: Bolts 17-22, 25 Nm
- Check 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.





Using a piston ring compressor, compress the piston 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.





Position the connecting rod cap on the appropriate connecting rod and alternately tighten the bolts in three stages as indicated.
- Stage l: 23 Nm
- Stage 2: 43 Nm
- Stage 3: 90 degrees

13. Check the connecting rod side clearance.
14. Rotate the crankshaft to make sure the crankshaft and pistons are operating correctly.





15. Install the oil pump.
- Tighten the bolts in the indicated tightening sequence.

16. NOTE: Oil pan baffle nuts are torqued-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 degrees (one-eighth turn)

17. NOTE: Lubricate a new O-ring seal with light engine oil before installation.





Position the oil intake tube and install the bracket nut in two stages.
- Stage 1: 5 Nm
- Stage 2: 45 degrees





18. Tighten 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: Left-hand shown, right-hand is similar.

NOTE: Left-hand and right-hand 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.
- Tighten the cylinder head bolts in the indicated tightening sequence in two stages.
- Stage 1: 40 Nm
- Stage 2: 90 degrees

22. NOTE: Right-hand shown, left-hand is similar.





Loosen the cylinder head bolts in the sequence shown.
- Loosen the bolts one full turn (360 degrees).

23. NOTE: Left-hand shown, right-hand is similar.





Tighten the cylinder head bolts in the indicated sequence in three stages.
- Stage 1: 40 Nm
- Stage 2: 90 degrees
- Stage 3: 90 degrees

24. Check 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: Left-hand shown, right-hand is similar.





Install the hydraulic lash adjusters.
- Lubricate the hydraulic lash adjusters with engine assembly lubricant prior to installation.

28. Install the left-hand camshafts.
- Lubricate the camshafts with engine assembly lubricant.

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





Install the left-hand camshaft caps in their original positions.
- Loosely install the camshaft cap bolts.

30. Install the right-hand camshafts.
- Lubricate the camshafts with engine assembly lubricant.

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





Install the right-hand 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.

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





Install the left-hand timing chain.
1 Install the left-hand chain guide and bolts (black material).
2 Install the crankshaft sprocket
3 Install the timing chain.





34. Grip the left-hand 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 left-hand 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 left-hand 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 left-hand timing chain tensioner.
1 Install the left-hand tensioner arm (black material).
2 Install the tensioner adapter plate left-hand, 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 right-hand timing chain.
1 Install the tensioner arm and bolts (tan material)
2 Install the crankshaft sprocket.
3 Install the timing chain.





40. Grip the right-hand 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 right-hand 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 right-hand 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 paperclip.





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

45. CAUTION: Crankshaft keyway must be in the 11 o'clock position before installation of the left-hand cylinder head roller finger followers.

NOTE: Check 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 left-hand roller finger followers.
- Lubricate the roller finger followers with Engine assembly lubricant.

46. CAUTION: Do not install the left-hand cylinder head camshaft journal thrust caps until camshaft journal caps are installed or damage to the thrust caps may occur.

NOTE: With left-hand cylinder head roller finger followers installed, align camshaft end play using thrust caps as a guide before tightening journal caps.





Tighten the left-hand camshaft cap bolts in the indicated sequence in several passes.





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.

49. CAUTION: The crankshaft keyway must be in the 3 o'clock position before installation of the right hand cylinder head roller finger followers. Failure to do so may lead to engine damage.

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





Install the right-hand roller finger followers.
- Lubricate the roller finger followers with engine assembly lubricant.

50. CAUTION: Do not install right-hand cylinder head camshaft journal thrust caps until camshaft journal caps are installed, or damage to the thrust caps may occur.

NOTE: With right-hand cylinder head roller finger followers installed, align camshaft end play using thrust caps as a guide before tightening journal caps.





Tighten the right-hand camshaft cap bolts in the indicated sequence in several passes.

51. NOTE: Left-hand shown, right-hand is similar.





Remove the right-hand and left-hand 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 WSL-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.
- Install the bolts and studs in the indicated sequence and tighten in two steps.
- First tighten the bolts and studs one quarter turn (90 degrees) after engine front cover contacts cylinder block and cylinder heads.





55. Install the remaining engine front cover bolts and studs and tighten in the indicated sequence.

56. NOTE: Lubricate the new O-ring seals with light engine oil before installation.





Install the sensors and wiring brackets.
- Install the CKP sensor.
- Install the CMP sensor.





57. Using special tools, install the crankshaft front oil seal.
- Lubricate the outer ring and sealing lip with engine oil.

58. NOTE: Before applying sealer, clean sealing surfaces to remove all residues that may interfere with the sealers ability to adhere.

Clean the sealing surfaces with Metal surface cleaner and 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.