Assembly
NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.
Special Tools:
1. CAUTION: Do not damage the cylinder
Remove the ring of carbon from the upper edge
2. Clean all reusable parts with a spatula and gasket eliminator, and check them for damage.
3. Thoroughly clean all threaded bores.
4. Available main bearing shell sizes.
NOTE: The main bearing shells are color coded.
- Size A: 2.145-2.152 mm (green)
- Size B: 2.140-2.147 mm (brown)
- Size C: 2.135-2.142 mm (yellow)
- Size D: 2.130-2.137 mm (blue)
5. NOTE: Use size "B" or "C" main bearing shells (see previous step).
Measure the crankshaft radial clearance
- Select the bearing shell according to previous step to obtain a bearing clearance of 0.020-0.040 mm.
- Measure the crankshaft end float.
7. Measure the camshaft radial clearance.
8. Measure the camshaft end float.
9. Measure the crankshaft.
10. Measure the camshafts.
11. Measure the cylinder bores.
12. Measure the pistons.
13. Measure the piston ring gaps.
14. Measure the piston ring axial clearance.
15. Check the cylinder head distortion.
16. Install the crankshaft.
- Position the main bearing shells into the cylinder block and the main bearing caps in place, and coat them with super premium engine oil SAE 5W-30.
1 Position the crankshaft in place.
NOTE: Do not tighten the main bearing cap bolts at this stage.
2 Install the main bearing caps.
17. NOTE: The connecting rods are numbered starting from the timing belt end. The connected valve recesses on the piston crown are on the intake side.
Install the pistons.
- Lubricate the pistons and cylinder liners with super premium engine oil SAE 5W-30.
- Distribute the piston ring gaps and the elements of the oil scraper ring evenly around the circumference (120 degrees).
- Using a piston ring compressor, compress the piston flings.
- Press pistons No. 1 and No. 4 into the cylinders using the handle of a hammer. Connecting rod bearing journals No. 1 and No. 4 must be at BDC.
- Check that the bearing shells are clean and dry and install them in the associated connecting rods and bearing caps.
NOTE: Use new connection" rod bearing cab bolts. Do not tighten the connecting rod bearing cap bolts at this stage.
- Install the bearing caps.
- Turn the crankshaft through 180 degrees and install pistons No. 2 and No. 3.
- Check that the bearing shells are clean and dry and install them in the associated connecting rods and bearing caps.
- Position the corresponding connecting rod bearing shells clean and dry into the connecting rods and the connecting rod bearing caps.
18. NOTE: The crankshaft must rotate freely; if necessary check and adjust the bearing clearances.
Install the main bearings and connecting rod bearings.
1 Tighten the main bearing bolts in two stages.
- Stage 1: 25 Nm.
- Stage 2: 60 degrees.
2 Tighten the connecting rod bearing bolts in two stages.
- Stage 1: 25 Nm.
- Stage 2: 90 degrees.
19. Install the rear oil seal carrier and the Crankshaft (CKP) Position Sensor with its bracket.
- Position a new oil seal carrier with a new seal in installation position and tighten the bolts finger tight.
1 Align the oil seal carrier so that the mating face of the oil seal carrier is between 0.3 mm and 0.8 mm below the cylinder block.
2 Tighten the four bolts.
3 Install the CKP sensor bracket.
20. Using the special tool, install the oil seal.
- Use three flywheel bolts.
21. Position the oil pump.
- Position the oil pump with a new gasket and tighten the bolts finger tight.
- Using a feeler gauge, align the oil pump on both sides so that the mating face is between 0.3 trim and 0.8 mm below the cylinder block.
22. Install the oil pump with a new crankshaft front oil seal.
- Tighten the bolts and check the alignment as described in the next step. Correct as necessary.
23. Align the lower crankcase.
- Coat the joints between the cylinder block and the oil pump/oil seal carrier with black silicone rubber.
- Position the lower crankcase in installation position with a new gasket and tighten the bolts finger tight.
NOTE: If the permissible overlaps or gaps are exceeded, use spacer shims as described in the next step.
- Align the lower crankcase using a straight edge so that the cylinder block and the lower crankcase are flush or do not exceed the following tolerances:
- Manual transaxle: 0.10 mm overlap to 0.25 mm gap.
- Automatic transaxle: 0.00 mm overlap to 0.25 mm gap.
24. Install the lower crankcase spacer shims as required.
- 0.26 to 0.50 mm gap, use 0.25 mm (yellow) spacer shims.
- 0.51 to 0.75 mm gap, use 0.50 mm (black) spacer shims.
25. Install the lower crankcase with a new gasket.
1 Tighten the bolts and check the alignment of the lower crankcase as described be fore. Correct as necessary.
2 Install the oil intake tube with a new gasket. Tighten the oil pump bolts first and then the bolt to the lower crankcase.
26. Preparatory operations for the installation of the oil pan.
- Two studs, M6 x 20-screw them in to guide the oil pan.
NOTE: The mating faces must be free of oil and gasket residue.
- Clean the oil pan using solvent to remove any oil residue or sludge.
27. NOTE: Install the oil pan within 10 minutes after applying the sealer.
Apply a 3 mm bead of sealer to the mating face of the oil pan.
28. NOTE: Tightening sequence.
Install the oil pan and screw in the drain plug with a new oil seal.
- Tighten the bolts in indicated sequence shown in two stages:
- Stage l: 6 Nm
- Stage 2: l0 Nm
29. NOTE: Remove any traces of thread-locking compound from the threaded bores on the crankshaft.
NOTE: Use new bolts.
Using the special tool, install the flywheel.
30. NOTE: Apply the high temperature grease thinly enough so that when the clutch disc is fitted onto the transmission input shaft, no grease is squeezed out from the splines.
Coat the drive splines of the clutch disc evenly with high temperature grease.
31. NOTE: Center the clutch disc on the pressure plate.
Using the special tool, install the clutch pressure plate and the clutch disc (if equipped).
1 Locate the clutch pressure plate in position with the centered clutch disc.
2 Tighten the bolts in several stages, a turn at a time, working diagonally.
3 Check the centering and correct as necessary.
32. Install the cylinder head.
1 Make sure the upright seat of the guide sleeves.
2 Position a new cylinder head gasket onto the cylinder block.
- Attach the cylinder head into the Engine lifting bracket workshop hoist by the lifting eyes and move it with the Floor crane into the installation position on the cylinder block.
33. CAUTION: The cylinder head bolts must not be tightened more than once.
NOTE: New un-oiled bolts must be installed.
NOTE: Tighten the bolts in the indicated sequence shown in three stages.
Install the cylinder head bolts.
- Stage 1: 20 Nm
- Stage 2: 40 Nm
- Stage 3: 90 degrees
34. NOTE: Use your thumb to press the locating pins on the gasket into the holes.
Press a new gasket into the oil feed flange.
35. Assemble the exhaust camshaft for installation.
1 Insert the oil feed ring into the oil feed flange.
2 Slide both components together onto the exhaust camshaft.
36. Thinly coat the camshaft bearing cap No. 5 with sealer.
37. Insert the camshafts.
- Lubricate the valve tappets with engine assembly lubricant and insert them.
- Lubricate the camshaft bearings with engine assembly lubricant.
- Insert the intake camshaft.
1 Hold the oil feed flange upwards during installation of the exhaust camshaft.
2 Position the oil feed ring hole at the top.
NOTE: Keep the oil feed flange away from the cylinder head when turning the flange to avoid damaging the gasket.
3 Turn the oil feed flange till the locating lug is in installation position on the cylinder head.
38. Insert new exhaust camshaft oil seal.
39. NOTE: The numbering is on the outside of the camshaft bearing caps.
Insert the camshaft bearing caps.
NOTE: Make sure the upright seat of the exhaust camshaft oil seal during tightening process of camshaft bearing cabs.
40. NOTE: Working evenly in several stages, screw in each bolt two turns at a time.
NOTE: Tightening sequence.
Tighten the camshaft bearing cap bolts.
41. Using the special tool, install in the intake camshaft oil seals.
42. NOTE: Make sure the locating lug of the oil feed flange is in installation position on the cylinder head during installation.
Screw in the oil feed flange bolts.
- Finger tighten the right-hand bolt.
- Finger tighten the left-hand bolt.
1 Tighten the right-hand bolt.
2 Tighten the left-hand bolt.
43. Insert new camshaft oil seals.
44. NOTE: After carrying out the check turn the hole right up to the top.
Check that the oil feed ring moves freely.
- If it is difficult to turn the oil feed ring, loosen the bolts on the oil feed flange and tighten them again as described in the previous step.
45. Set the crankshaft to TDC on cylinder No. 1.
46. NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key points straight up.
Using the special tool, set the crankshaft to TDC.
- Remove the blanking plug.
47. Set cylinder No. 4 to "valves rocking" and install the special tool.
1 Using an open-ended wrench, turn the camshafts by the hexagon in the normal direction of rotation.
2 Slide the special tool onto the ends of both camshafts.
48. NOTE: If the lug is not bent or centered between the oil bores and the mark, install a new exhaust camshaft pulley.
Installation position of the exhaust camshaft pulley.
1 The lug is centered between the oil bores and the mark.
2 The lug must locate in the hole.
49. NOTE: Install the bolts in place but do not tighten them. It must be possible to turn the camshaft pulleys on the camshafts.
Slide the camshaft pulleys onto the camshafts and insert the bolts.
50. Install a new gasket in the water pump.
1 Position the gasket in the water pump.
2 Secure the gasket by bending the tabs over.
51. CAUTION: Do not rotate the crankshaft; as necessary check that it is still resting against the special tool 303-574.
NOTE: Install the bolts in place butt do not tighten them at this stage.
NOTE: New O-ring seal for the exhaust camshaft pulley.
Slide the camshaft pulleys onto the camshafts, screw in the bolts and position the new timing belt in place, working counterclockwise.
1 Position the hollow bolt.
2 Install the bolt finger tight.
52. Using special tool, immobilize the flywheel.
53. CAUTION: Do not rotate the crankshaft; as necessary check that it is still resting against the special tool 303-574.
NOTE: The lug of the timing belt tensioner should not be hooked in the sheet metal cover during timing belt installation.
1 Slide the crankshaft timing belt pulley and the thrust washer onto the crankshaft.
2 Install the water pump.
3 Install the lower idler pulley.
4 Install the upper idler pulley.
5 Starting from the crankshaft pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
6 Install the timing belt tensioner and screw the bolt in five turns.
54. CAUTION: Tension the timing belt working counterclockwise.
NOTE: Incorrect timing belt tension will cause incorrect valve timing.
Tension the timing belt.
1 Hook the timing belt tensioner into the sheet metal cover and loosely screw in the bolt.
2 Tension the belt by turning the timing belt tensioner counterclockwise until the pointer and the mark are lined up.
55. NOTE: Hold the camshaft pulley with the special tool to stop it from turning.
Tighten the camshaft pulleys.
1 Tighten the intake camshaft pulley bolt.
NOTE: Hold the exhaust camshaft by the hexagon with an open-ended wrench to stop it from turning.
2 Tighten the exhaust camshaft pulley bolt to tightening torque.
56. Remove the special tool 303-574.
57. Remove the special tool 303-465 from the camshafts.
58. NOTE: Hold the camshaft by the hexagon with an open-ended wrench to stop it from turning.
Tighten the exhaust camshaft pulley bolt to tightening torque.
59. NOTE: If necessary, only turn engine in the direction of engine rotation by the crankshaft.
Check camshaft timing.
- Set the crankshaft to TDC on cylinder No. 1 as described before.
- If special tool 303-465 does not install into both camshaft slots, loosen the tensioner, the intake and exhaust camshaft pulley bolts and tension the timing belt as described in the steps before.
60. NOTE: Install a new blanking plug.
Screw in the new blanking plug on the exhaust camshaft pulley.
61. Install the valve cover with a new gasket and a new solenoid valve oil seal.
- Install the spark plugs.
1 Screw in the ten bolts.
2 Connect the spark plug wires.
3 Install the cylinder head appearance cover.
62. Using the special tool, install the engine front cover.
1 Install the lower part of the engine front cover.
2 Install the crankshaft pulley/vibration damper.
NOTE: Check the seating of the gasket and adjust it as necessary.
3 Install the upper part of the engine front cover.
4 Install the center part of the engine front cover.
5 Install the accessory drive belt idler pulley.
6 Install the water pump pulley.
63. Install the crankcase ventilation tube.
- Use a new gasket.
1 Install in the three bolts.
2 Connect the crankcase Ventilation tube.
64. Install the ancillary components on the exhaust side of the engine.
1 Air Conditioning (A/C) compressor bracket.
2 Power steering pump bracket to cylinder head.
3 Power steering pump bracket to cylinder block.
4 Coolant hose to thermostat housing and water pump.
5 Three Way Catalytic Converter (TWC) bracket.
65. Attach the engine to the Engine lifting bracket by the engine lifting eyes and remove it from the Assemble stand.
- Leave the engine attached to the Engine lifting bracket and rest the engine on the Assemble stand.
66. Install the ancillary components on the intake side of the engine:
1 Position the TWC into the exhaust manifold and install the exhaust manifold bracket.
2 Install in the oil pressure switch.
3 Install in the Knock Sensor (KS).
4 Install a new oil filter. Coat the oil filter seal with Super premium engine oil SAE 5W-30 before assembly.
5 Install the generator bracket.
6 Install the generator bracket.
67. Install the TWC to exhaust manifold.
68. Install the TWC bracket bolt.
69. Install the heat shield.
- Unhook the engine lifting eye from the Engine lifting bracket and remove it.
- Install the heat shield together with the engine oil level indicator tube and the lifting eye.
- Hook the lifting eye back into the Engine lifting bracket.
70. Install the intake manifold.
1 Install the seven bolts and two nuts.
2 Connect the solenoid valve electrical connector and press in the rubber seal.
71. Install the generator.
1 Install the bolts.
2 Connect the generator electrical connectors.
72. Connect the oil pressure switch and the KS electrical connectors.
73. Connect the CMP sensor and the ECT sensor electrical connectors.
- Attach the wiring to the EI coil.