Engine Assembly Procedure

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Installing Crankshaft Key Into Keyway On Crankshaft
Courtesy of FORD MOTOR CO.

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.
  Fig 2: Reading Code On Crankshaft Flange
  Courtesy of FORD MOTOR CO.
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.
Fig 3: Crankshaft & Block Code Graph
Courtesy of FORD MOTOR CO.
Install the main bearings into the cylinder block.

Fig 4: Installing Main Bearings Into Cylinder Block
Courtesy of FORD MOTOR CO.
Install the main bearings into the lower cylinder block.

Fig 5: Installing Main Bearings Into Lower Cylinder Block
Courtesy of FORD MOTOR CO.
Install the crankshaft thrust bearing.

Fig 6: Installing Crankshaft Thrust Bearing
Courtesy of FORD MOTOR CO.

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

Fig 7: Applying Silicone Gasket & Sealant

Courtesy of FORD MOTOR CO.

Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the cylinder block as shown.
Apply Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-H to the crankshaft main and rod bearing journals.
Position the crankshaft in the cylinder block.

Fig 8: Identifying Position Of Crankshaft In Cylinder Block
Courtesy of FORD MOTOR CO.

CAUTION: Fasteners No. 1, 5, 6, 7, 8 are studs. Fasteners No. 18-22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 2-4, 17 are M8 x 1.25 mm x 95.3 mm (0.05 in x 3.75 in) bolts. Fasteners 9-16 are M10 x 1.5 mm x 106 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position or engine damage can result.

Fig 9: Lower Cylinder Block Tightening Sequence

Courtesy of FORD MOTOR CO.

Position the lower cylinder block and install the bolts and studs in the sequence shown in four stages.
- Stage 1: Tighten fasteners 1-8 to 25 Nm (18 lb-ft).
- Stage 2: Tighten fasteners 9-16 to 40 Nm (30 lb-ft).
- Stage 3: Tighten fasteners 1-16 90 degrees.
- Stage 4: Tighten fasteners 17-22 to 25 Nm (18 lb-ft).
Using the special tool, measure the crankshaft end play.

Fig 10: Measuring Crankshaft End Play
Courtesy of FORD MOTOR CO.
Using the special tool, install the crankshaft rear oil seal.

Fig 11: Installing Crankshaft Rear Oil Seal Using Special Tool
Courtesy of FORD MOTOR CO.
Position the flexplate and install the bolts.

Fig 12: Identifying Position Of Flexplate
Courtesy of FORD MOTOR CO.
Mount the engine on an engine stand.
Apply Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-H to the cylinder bores.
Using the special tools, install the piston and connecting rod assemblies.

Fig 13: Installing Piston & Connecting Rod Assemblies
Courtesy of FORD MOTOR CO.
Check connecting rod bearing clearance. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION for basic mechanical concerns.
Install the connecting rod caps and tighten the bolts in two stages.
- Stage 1: Tighten to 23 Nm (17 lb-ft).
- Stage 2: Tighten to 43 Nm (32 lb-ft).
Fig 14: Installing Connecting Rod Caps & Tighten Bolts In Two Stages
Courtesy of FORD MOTOR CO.
Position the oil pump and install the bolts in the indicated sequence.

Fig 15: Identifying Position Of Oil Pump
Courtesy of FORD MOTOR CO.
Position the oil pan baffle. Install the nuts and tighten in two stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten 45 degrees.
Fig 16: Identifying Position Of Oil Pan Baffle
Courtesy of FORD MOTOR CO.
Install a new O-ring seal on the oil pump screen and pick-up tube.

Fig 17: Installing A New O-ring Seal On Oil Pump Screen & Pick-Up Tube
Courtesy of FORD MOTOR CO.
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 and tighten in two stages.
  - Stage 1: Tighten to 5 Nm (44 lb-in).
  - Stage 2: Tighten 45 degrees.
Install the power steering/engine support bracket.

Fig 19: Installing Power Steering/Engine Support Bracket
Courtesy of FORD MOTOR CO.
Install the oil separator.
- Install the two bolts.
Fig 20: Installing Oil Separator
Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. Clean all sealing surfaces with metal surface cleaner.

NOTE: New cylinder head bolts must be installed. They are torque-to-yield designed and cannot be reused.

Fig 21: LH Cylinder Head Tightening Sequence

Courtesy of FORD MOTOR CO.

Position the LH cylinder head and gasket and install the bolts. Tighten the bolts in six stages, in the sequence shown:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten bolts 90 degrees.
- Stage 3: Loosen one full turn.
- Stage 4: Tighten to 40 Nm (30 lb-ft).
- Stage 5: Tighten 90 degrees.
- Stage 6: Tighten 90 degrees.
Install the crankshaft damper bolt and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).

Fig 22: Installing Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.
Apply Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-H to the LH and RH camshaft followers.

CAUTION: The camshaft followers must be installed in the original position.

NOTE: RH shown; LH similar.

Fig 23: Installing LH & RH Camshaft Followers

Courtesy of FORD MOTOR CO.

Install the LH and RH camshaft followers.
Apply Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-H to the LH and RH camshafts.
Install the LH and RH camshafts.
- Locate the camshafts as shown.
Fig 24: Installing LH & RH Camshafts
Courtesy of FORD MOTOR CO.
Position the LH camshaft caps and install the bolts in the sequence shown.

Fig 25: LH Camshaft Caps Bolt Installation Sequence
Courtesy of FORD MOTOR CO.

CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.

Fig 26: RH Camshaft Caps Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Position the RH camshaft caps and install the bolts in the sequence shown.
Remove the crankshaft damper bolt.

Fig 27: Removing Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.

NOTE: Install the sprockets with the timing marks out.

Fig 28: Installing Crankshaft Sprockets

Courtesy of FORD MOTOR CO.

Install the crankshaft sprockets.

NOTE: LH shown, RH similar.

Fig 29: Identifying Position Of Chain Tensioner In A Soft-Jawed Vise

Courtesy of FORD MOTOR CO.

Position the chain tensioner in a soft-jawed vise.

NOTE: LH shown, RH similar.

Fig 30: Holding Chain Tensioner Ratchet Lock Mechanism

Courtesy of FORD MOTOR CO.

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

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

Fig 31: Retaining Tensioner Piston
Courtesy of FORD MOTOR CO.
If the timing marks on the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and the 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.
3. Continue counting to link 42 and mark the link.
Fig 32: Identifying Mark On Crankshaft & Camshaft Timing Marks
Courtesy of FORD MOTOR CO.
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.
Fig 33: Aligning Marks On Timing Chain With Marks On Camshaft
Courtesy of FORD MOTOR CO.
Install the LH timing chain tensioner arm and the LH timing chain tensioner.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the bolt.
Fig 34: Installing LH Timing Chain Tensioner Arm & LH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is at the 3 o'clock position.

Fig 35: Installing Crankshaft Damper Bolt & Rotate
Courtesy of FORD MOTOR CO.
Verify that the RH camshafts are correctly positioned.

Fig 36: Verifying That RH Camshafts Are Correctly Positioned
Courtesy of FORD MOTOR CO.
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.
Fig 37: Identifying Position of RH Timing Chain & Chain Guide & Install Bolts
Courtesy of FORD MOTOR CO.
Install the RH timing chain tensioner arm and the RH timing chain tensioner.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the bolts.
Fig 38: Installing RH Timing Chain Tensioner Arm & RH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Remove the LH and the RH timing chain tensioner piston retaining wires.

CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.

Fig 39: Rotating Crankshaft Counterclockwise 120 Degrees To Top Dead Center

Courtesy of FORD MOTOR CO.

Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC). 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 the crankshaft timing marks.
3. There should be 30 chain links between the camshaft and the crankshaft timing marks.
Remove the crankshaft damper bolt.

Fig 40: Removing Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.

CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "20-25-34Y-30M" (color blue).

Fig 41: Installing Ignition Pulse Wheel

Courtesy of FORD MOTOR CO.

Install the ignition pulse wheel.
Install the special tool to hold the flexplate.

Fig 42: Installing Special Tool To Hold Flexplate
Courtesy of FORD MOTOR CO.
Install three gaskets in the front cover.

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

Fig 43: Installing & Bolts Tightened Within Six Minutes Of Sealant

Courtesy of FORD MOTOR CO.

Apply a 6 mm (0.24 in) dot of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the cylinder block to lower cylinder block and cylinder head mating surfaces.

NOTE: Fasteners No. 1, 3, 4, 8, 10, 11, 14, 15 and 16 are studs.

Fig 44: Installing Bolts & Studs In Sequence

Courtesy of FORD MOTOR CO.

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

Fig 45: Installing Crankshaft Front Oil Seal
Courtesy of FORD MOTOR CO.

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

Fig 46: Applying Dot Of Silicone Gasket & Sealant

Courtesy of FORD MOTOR CO.

Apply a 10 mm (0.24 in) dot of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the front cover to cylinder block mating surface.
Position the oil pan and gasket and loosely install the bolts and studs in the indicated sequence.

Fig 47: Oil Pan Bolts & Studs Installation Sequence
Courtesy of FORD MOTOR CO.
Align the transaxle face of the oil pan with the rear of the cylinder block. The pan should be 0.00 mm (0.0 in) - 0.25 mm (0.009 in) under flush. Assemblies that are between 0.26 (0.01 in) - 0.50 mm (0.019 in) should be shimmed using either one or two 0.25 mm (0.009 in) gold shims. Assemblies that are between 0.51 mm (0.20 in) - 0.75 mm (0.029 in) should be shimmed using either one or two 0.50 mm (0.019 in) silver shims. If the pan measures greater than 0.75 mm (0.029 in) or the pan is over flush of the cylinder block, the entire pan assembly must be removed and a new one installed.
Tighten the oil pan bolts and studs in the sequence shown.

Fig 48: Tightening Oil Pan Bolts & Studs In Sequence
Courtesy of FORD MOTOR CO.
Install a new seal on the oil level indicator tube.

Fig 49: Installing A New Seal On Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
Install the oil level indicator tube and install the bolt.

Fig 50: Installing Oil Level Indicator Tube & Install Bolt
Courtesy of FORD MOTOR CO.

NOTE: Clean the keyway and slot using metal surface cleaner ZC-21 meeting Ford specification WSE-MSB392-A before applying silicone gasket and sealer.

NOTE: The crankshaft damper must be installed and the bolt tightened with in four minutes of sealant application.

Fig 51: Applying Silicone Gasket & Sealant

Courtesy of FORD MOTOR CO.

Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A to the end of the crankshaft damper keyway slot.

NOTE: Lubricate the outside diameter sealing surface with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP meeting Ford specification WSS-M2C153-A.

Fig 52: Installing Crankshaft Vibration Damper

Courtesy of FORD MOTOR CO.

Using the special tool, install the crankshaft vibration damper.
Install the crankshaft vibration damper washer and tighten the bolt in four stages.
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn (360 degrees).
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten to 90 Nm (66 lb-ft).
Fig 53: Installing Crankshaft Vibration Damper Washer & Tighten Bolt In Four Stages
Courtesy of FORD MOTOR CO.
Install new gaskets in the valve covers.

NOTE: The valve cover must be installed and the bolts and studs tightened with in six minutes of sealant application.

NOTE: LH shown; RH similar.

Fig 54: Applying Dot Of Silicone Gasket

Courtesy of FORD MOTOR CO.

Apply a 8 mm (0.31 in) dot of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A at the cylinder block to front cover mating surface of the LH and RH valve covers.
Position the RH valve cover and install the bolts and studs in the sequence shown.

Fig 55: Installing Bolts & Studs In Sequence
Courtesy of FORD MOTOR CO.
Position the LH valve cover and install the bolts and studs in the sequence shown.

Fig 56: RH Valve Cover Bolts & Studs Installation Sequence
Courtesy of FORD MOTOR CO.
Install the spark plugs.

Fig 57: Installing Spark Plugs
Courtesy of FORD MOTOR CO.

NOTE: RH shown; LH similar.

Fig 58: Installing Six Coil-On-Plugs

Courtesy of FORD MOTOR CO.

Apply a light film of Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford Specification ESE-M1C171-A to the interior of the spark plug boot prior to installation.
Install the six coil-on-plugs and install the bolts.
Install new gaskets in the lower intake manifold.
Position the knock sensor and install the bolt.

Fig 59: Identifying Position Of Knock Sensor & Install Bolt
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 60: Removing Special Tool
Courtesy of FORD MOTOR CO.
Position the coolant bypass tube and connect the hoses.

Fig 61: Identifying Position Of Coolant Bypass Tube & Connect Hoses
Courtesy of FORD MOTOR CO.
Install the oil pressure sender and the block heater.

Fig 62: Installing Oil Pressure Sender & Block Heater
Courtesy of FORD MOTOR CO.
Install the oil cooler.

Fig 63: Installing Oil Cooler
Courtesy of FORD MOTOR CO.
Install the radio ignition noise suppressor electrical connector.

Fig 64: Installing Radio Ignition Noise Suppressor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the generator support bracket.

Fig 65: Installing Generator Support Bracket
Courtesy of FORD MOTOR CO.
Install the power steering pump.

Fig 66: Installing Power Steering Pump
Courtesy of FORD MOTOR CO.
Install the power steering pump pulley.

Fig 67: Installing Power Steering Pump Pulley
Courtesy of FORD MOTOR CO.
Install the oil filter.

Fig 68: Installing Oil Filter
Courtesy of FORD MOTOR CO.
Connect the coolant hoses at the oil cooler.

Fig 69: Connecting Coolant Hoses At Oil Cooler
Courtesy of FORD MOTOR CO.
Install the water pump assembly.

Fig 70: Installing Water Pump Assembly
Courtesy of FORD MOTOR CO.
Position a new gasket and tighten the exhaust manifold nuts in the sequence shown.

Fig 71: Tightening Exhaust Manifold Nuts In Sequence
Courtesy of FORD MOTOR CO.
Install the engine lift bracket.

Fig 72: Installing Engine Lift Bracket
Courtesy of FORD MOTOR CO.
Position the gasket and install the lower intake manifold.

Fig 73: Installing Lower Intake Manifold
Courtesy of FORD MOTOR CO.
Position and connect the engine control sensor wiring in the locations shown.
- coils-on-plugs
- fuel injectors
Fig 74: Connecting Engine Control Sensor Wiring
Courtesy of FORD MOTOR CO.
Connect the radio interference capacitor.

Fig 75: Connecting Radio Interference Capacitor
Courtesy of FORD MOTOR CO.
Connect the crankshaft and camshaft position sensor electrical connectors.

Fig 76: Connecting Crankshaft & Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Install new gaskets in the upper intake manifold.
Install the upper intake manifold.

Fig 77: Installing Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Install and connect the engine control wire harness.

Fig 78: Connecting Engine Control Wire Harness
Courtesy of FORD MOTOR CO.
Connect the coolant temperature sender and the oil pressure switch.

Fig 79: Connecting Coolant Temperature Sender & Oil Pressure Switch
Courtesy of FORD MOTOR CO.
Connect the vacuum line from the fuel pressure damper.

Fig 80: Connecting Vacuum Line From Fuel Pressure Damper
Courtesy of FORD MOTOR CO.
Connect the engine control sensor wiring to the upper intake manifold.

Fig 81: Connecting Engine Control Sensor Wiring To Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the EGR vacuum regulator and the differential pressure feedback EGR electrical connectors.

Fig 82: Connecting EGR Vacuum Regulator
Courtesy of FORD MOTOR CO.
Install the PCV tube.

Fig 83: Installing PCV Tube
Courtesy of FORD MOTOR CO.
Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.

Fig 84: Connecting Idle Air Control Valve
Courtesy of FORD MOTOR CO.