Steps 1 - 70

NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.

Engine











Special Tool(s)

1. WARNING: Eye protection is required to be worn during the use of compressed air. Failure to wear eye protection could result in possible personal injury.

Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.





2. If removed, install the crankshaft key into the keyway on the crankshaft.





3. NOTE: This procedure is for selecting bearings using a new crankshaft.

Select the crankshaft main bearings for each crankshaft journal.
1 Read the code on the crankshaft flange.
2 Read the code on the cylinder block rear face.
- The first two numbers after the asterisk make up the code for main No.1 and the next two numbers for main No. 2.
- The first two numbers after the second asterisk make up the code for main No.3 and the last two numbers for main No. 4.





4. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
- For example: If the block code is *0609*0711* and the crankshaft code is *8480*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 84 crankshaft row. Mains 2, 3 and 4 should all be grade 2.





5. Install the main bearings into the cylinder block.





6. Install the main bearings into the lower cylinder block.





7. Install the crankshaft thrust bearing.





8. If removed, install the crankshaft key.





9. CAUTION: The lower cylinder block must be installed and the bolts tightened within four minutes of applying the sealant.

Apply gasket and sealant to the cylinder block as shown.
10. Apply engine oil to the crankshaft main and rod bearing journals.





11. Position the crankshaft in the cylinder block.





12. CAUTION: Fasteners No. 1, 5, 6, 7, 8 are studs. Fasteners No. 18-22 are M8 x 1.25 mm x 793 mm (0.05 in x 3.12 inch) bolts. Fasteners No. 2-4,17 are M8 x 1.25 mm x 953 mm (0.05 in x 3.75 inch) bolts. Fasteners 9-16 are M10 x 1.5 mm x 106 mm (Q06 in x 4.17 inch) bolts. The bolts and studs must be installed in the correct position or engine damage may result.

Position the lower cylinder block and install the bolts and studs.
- Tighten the bolts and studs in the sequence shown in four stages.
- Stage 1: Tighten fasteners 1-8 to 25 Nm (18 ft. lbs.).
- Stage 2: Tighten fasteners 9-19 to 40 Nm (30 ft. lbs.).
- Stage 3: Tighten fasteners 1-16 90°.
- Stage 4: Tighten fasteners 17-22 to 25 Nm (18 ft. lbs.).





13. Using the special tool, measure crankshaft end play.





14. Using the special tools, install the crankshaft rear oil seal.





15. Position the flexplate and install the bolts.
16. Mount the engine on an engine stand.
17. Apply engine oil to the cylinder bores.





18. Using the special tool, install the piston and connecting rod assemblies.





19. Install the connecting rod caps and bolts.
- Tighten the bolts in two stages.
- Stage 1: Tighten to 23 Nm (17 ft. lbs.).
- Stage 2: Tighten to 43 Nm (32 ft. lbs.).





20. Position the oil pump and install the bolts in the indicated sequence.





21. Position the oil pan baffle and install the nuts.
- Tighten the nuts in two stages.
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Tighten 45°.





22. Install a new O-ring seal on the oil pump screen and pick-up tube.





23. Install the oil pump screen and pick up tube.
1 Position the oil pump screen and pick up tube.
2 Install the bolts.
3 Install the nut. Tighten the nut in two stages.
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Tighten 45°.





24. Position the oil separator, gasket, and install the bolts.





25. NOTE: RH shown, LH similar.

Position the LH and RH cylinder heads, gaskets, and install the bolts.
- Tighten the bolts in the sequence shown in six stages.
- Stage 1: Tighten to 40 Nm (30 ft. lbs.).
- Stage 2: Tighten to 90 Nm (66 ft. lbs.).
- Stage 3: Loosen one full turn.
- Stage 4: Tighten to 40 Nm (30 ft. lbs.).
- Stage 5: Tighten 90°.
- Stage 6: Tighten 90°.





26. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate Top Dead Center (TDC).
27. Apply engine oil to the LH and RH camshaft followers.





28. NOTE: RH shown, LH similar.

Install the LH and RH camshaft followers.
29. Apply engine oil to the LH and RH camshafts.





30. Install the LH and RH camshafts.
- Locate the camshafts as shown.





31. Position the RH camshaft caps and install the bolts in the sequence shown.





32. Position the LH camshaft caps and install the bolts in the sequence shown.





33. CAUTION: The camshaft bearing caps are positional and must be installed in their original locations and orientations or engine damage can occur.

Verify that the camshaft bearing caps are in the correct locations.





34. Install the camshaft oil seal retainer.





35. NOTE: Lubricate the camshaft oil seal with engine oil.

Install a new camshaft oil seal.
- Using the special tools positioned over the oil seal, turn to install the seal.





36. Using the special tool, install the water pump drive pulley.





37. Remove the crankshaft damper bolt.





38. NOTE: Install the sprockets with the timing marks out.

Install the crankshaft sprockets.





39. NOTE: LH shown, RH similar.

Position the chain tensioner in a softjawed vise.





40. NOTE: LH shown, RH similar.

Hold the chain tensioner ratchet lock mechanism away. Turn the ratchet stem with a small pick.

41. CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Slowly compress the timing chain tensioner.





42. Retain the tensioner piston with a 1.5 mm (0.06 inch) wire or paper clip.





43. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
1 Mark any link to use as the crankshaft timing mark.
2 Starting with the crankshaft timing mark, count 29 links and mark the link as the exhaust cam sprocket timing mark.
3 Continue counting to 42. Mark the link as the intake sprocket timing mark.





44. Position the LH timing chain and guide and install the bolts.
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.





45. Install the LH timing chain tensioner and tensioner arm.
1 Install the tensioner arm.
2 Position the tensioner.
3 Install the bolts.





46. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120° until the crankshaft keyway is in the 3 o'clock position.





47. Verify that the RH camshafts are correctly positioned.





48. Position the RH timing chain and chain guide and install the bolts.
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.





49. Install the RH timing chain tensioner and tensioner arm.
1 Install the tensioner arm.
2 Position the tensioner.
3 Install the bolts.
50. Remove the LH and RH timing chain tensioner piston retaining wires.





51. Verify the timing with the following steps.
1 There should be 12 chain links between the front camshaft timing marks.
2 There should be 27 chain links between the camshaft and crankshaft timing marks.
3 There should be 30 chain links between the camshaft and crankshaft timing marks.





52. Remove the crankshaft damper bolt.





53. Install the LH and RH spark plugs.





54. CAUTION: This pulse wheel is used in several different engines.

Install the pulse wheel with the key way in the slot stamped 30 or 30RFF only.
- Install the ignition pulse wheel.





55. Install the special tool to hold the flexplate.





56. Install a new gasket in the front cover.





57. NOTE: The front cover must be installed and the bolts tightened within six minutes of sealant application.

Apply a 6 mm (0.24 inch) dot of gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.





58. NOTE: Fasteners No. 1 and 6 are studs.

Position the front cover and install the bolts and studs in the sequence shown.
59. Using the special tool, install the crankshaft front oil seal.





60. NOTE: The oil pan must be installed and the bolts tightened within six minutes of sealant application.

Apply a 10 mm (0.24 inch) dot of gasket and sealant to the front cover-to-cylinder block mating surface.





61. NOTE: Fasteners No. 12 and 13 are studs.

Position the oil pan and gasket and loosely install the bolts and studs in the indicated sequence.
62. Align the transaxle face of the oil pan with the rear of the cylinder block. The pan should be 0.00 mm (0.0 inch) - 0.25 mm (0.009 inch) under flush. Assemblies that are between 0.26 (0.01 inch) - 0.50 mm (0.019 inch) should be shunned using either one or two 0.25 mm (0.009 inch) gold shims. Assemblies that are between 0.51 mm (0.20 inch) - 0.75 mm (0.029 inch) should be shimmed using either one or two 0.50 mm (0.019 inch) silver shims. If the pan measures greater than 0.75 mm (0.029 inch) or the pan is over flush of the cylinder block, the entire pan assembly must be removed and a new one installed.





63. Tighten the oil pan bolts and studs in the sequence shown.





64. Install the oil pressure sensor.





65. Install a new seal on the oil level indicator tube.





66. Install the oil level indicator tube and install the bolt.





67. Install a new oil filter.





68. NOTE: The crankshaft damper must be installed and the bolt tightened within six minutes of sealant application.

Apply gasket and sealant to the end of the crankshaft damper keyway slot.





69. Using the special tool, install the crankshaft vibration damper.





70. Install the crankshaft vibration damper washer and bolt.
- Tighten the bolt in four stages.
- Stage 1: Tighten to 120 Nm (89 ft. lbs.).
- Stage 2: Loosen one full turn (360°).
- Stage 3: Tighten to 50 Nm (37 ft. lbs.).
- Stage 4: Tighten to 90 Nm (66 ft. lbs.).