| Assembly Special Tool(s) | | Universal Flange Holding Wrench 205-072 (15-030A) | | | Gauge, Bolt Angle 303-174 (21-540) | | | Timing Peg, Crankshaft TDC 303-193 (21-104) | | | Installer, Camshaft Seal 303-199A (21-110A) | | | Alignment Plate, Camshaft 303-376 (21-162B) | | | Locking Tool, Flywheel 303-393 (21-168) | | | Remover/Installer, Hose Clamp 303-397 (24-003) | | | Mounting Stand 303-435 (21-187) | | | Mounting Bracket for 303-435 303-435-06 (21-031B) | | | Aligner, Oil Pump 303-652 (21-230) | | | Aligner, Clutch Disc 308-204 (16-067) | | | Alignment Peg, Crankshaft Position Sensor bracket 310-057 (23-049) | General Equipment Micrometer Feeler gauges Internal micrometer Piston ring compressor Dial indicator gauge holding fixture Dial indicator gauge Plastigage Materials Name Specification Sealant WSE-M4G323-A4 Sealant WSK-M2G348-A5 Engine oil SAE 5W 30 WSS-M2C912-A1 Assembly All vehicles CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines. | | -
Coat the main bearing journals, bearing shells and thrust half washers with clean engine oil. | | | -
CAUTION:Install the main bearing upper and lower shells in the correct order Install the main bearing shells to the cylinder block and to the main bearing caps. | | | -
Position the crankshaft in the cylinder block. | | | -
NOTE:The grooves in the thrust half washers must face outwards. Install the crankshaft thrust half washers into the third main bearing with oil grooves facing outwards. | | | -
NOTE:Install the main bearing caps with arrows pointing forward. Caps are identified 1, 2, 3, 4, 5 from the front to the rear. Install the crankshaft. - Tighten the bolts in three stages in the sequence shown.
- Stage 1: Tighten the bolts 1 through 10 to 45 Nm.
- Stage 2: Tighten the bolts 1 through 10 to 70 Nm.
- Stage 3: Tighten the bolts 1 through 10 to 60 degrees.
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NOTE:Install the pistons with the arrows pointing to the front of the engine. NOTE:The piston ring gaps and oil supply ring elements must be distributed evenly around the circumference. Using a suitable piston ring compressor, install the pistons. - Install clean and dry connecting rod bearing shells in the connecting rods.
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CAUTION:Connecting rod bearing cap bolts must only be used two times. NOTE:Stamp the bolt heads with a center punch to indicate usage. NOTE:The big-end bearing caps identification marks must point to the front of the engine. Install the connecting rod bearing caps. - Tighten the bolts in four stages.
- Stage 1: Tighten the bolts finger tight.
- After installation lubricate the journals with engine oil.
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NOTE:Install a new timing chain rear housing gasket. Install the timing chain rear housing. | | | -
NOTE:Install a new ladder frame gasket. Install the ladder frame (14 bolts). - Align the ladder frame flush with the cylinder block.
- Tighten the bolts in the sequence shown.
| Vehicles with air conditioning | | -
Install the air conditioning (A/C) compressor retaining bracket. | All vehicles | | -
NOTE:Install a new oil pump pickup tube O-ring seal. Install the oil pump pick-up tube. | | | -
NOTE:Install new O-ring seals. Install the oil pump connecting pipe. | | | -
NOTE:Do not damage the mating faces. NOTE:The mating faces and blind holes must be free of oil and sealer residue. Clean the mating faces of the oil pan and ladder frame. | | | -
CAUTION:Make sure that the sealer does not enter the ladder frame blind holes. Failure to follow this instruction may result in damage to the engine assembly. NOTE:Install the oil pan within ten minutes of applying the sealer. NOTE:Once the oil pan has contact with the ladder frame it must not be removed. Install the oil pan. - Apply a 2.5 mm diameter bead of sealant to the ladder frame (dotted line).
- Tighten bolts and nuts in the sequence shown.
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NOTE:Inspect the oil pan drain plug seal for damage. Install a new drain plug and seal if required. Install the drain plug. | | | -
NOTE:A new crankshaft rear oil seal carrier is supplied with an alignment sleeve that must be removed following installation. NOTE:Do not fully tighten the crankshaft rear oil seal carrier retaining bolts at this stage. Install the crankshaft rear oil seal carrier. | | | -
Tighten the crankshaft rear oil seal carrier retaining bolts. | | | -
Remove the crankshaft rear oil seal carrier alignment sleeve. | | | -
NOTE:Do not fully tighten the crankshaft position (CKP) sensor retaining bracket bolts at this stage. Install the CKP sensor retaining bracket. | | | -
NOTE:Install new flywheel bolts. Using the special tool, install the flywheel. - Tighten the bolts in three stages in the sequence shown.
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Using the special tool, centralize the clutch disc on the pressure plate. | | | -
CAUTION:Tighten the clutch pressure plate retaining bolts finger tight and then by two turns at a time in the sequence shown to the specified torque. Using the special tool, install the clutch disc and pressure plate. | | | -
Using the special tool, install the CKP sensor retaining bracket. | | | -
Install the coolant distribution pipe. | | | -
Using the special tool, attach the upper coolant hose to the coolant distribution pipe. | | | -
NOTE:Install a new fuel injection pump gasket. Install the fuel injection pump. | | | -
Install the fuel injection pump bracket. | | | -
Install the timing chain, sprockets and guides. | | | -
NOTE:Do not tighten the fuel injection pump sprocket bolts at this stage. Install the fuel injection pump sprocket. | | | -
Install the timing chain tensioner. | | | -
Using the special tool, install the timing chain housing cover. - Tighten the bolts in the sequence shown in three stages.
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Install the accessory drive belt idler. | | | -
Using the special tool, install the crankshaft pulley. - Tighten the bolt in two stages.
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Install the special tool. - Remove the cylinder block blanking plug.
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NOTE:Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft to top dead center (TDC). - Turn the crankshaft slowly until the crankshaft stops.
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NOTE:Using a 6 mm drill bit, set the fuel injection pump to crankshaft TDC. Install the fuel injection pump sprocket. | | | -
NOTE:Only turn the crankshaft in the normal direction of rotation. NOTE:Using a suitable marker, mark the crankshaft pulley to show TDC. Turn the crankshaft 90 degrees. | | | -
NOTE:Install a new water pump gasket. Install the water pump. | | | -
Using the special tool, install the water pump pulley. | | | -
CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole/tooth marked). Install a new cylinder head gasket. | | | -
NOTE:The turbocharger oil return hose must be attached when the cylinder head is installed. Install the cylinder head. | | | -
CAUTION:Install new cylinder head bolts. Install the cylinder head bolts. - Using the special tool, tighten the bolts in four stages in the sequence shown.
- Stage 1: Tighten the bolts 1 through 10 to 20 Nm.
- Stage 2: Tighten the bolts 1 through 10 to 54 Nm.
- Stage 3: Tighten the bolts 1 through 10 to 90 degrees.
- Stage 4: short bolts: 70 degrees, long bolts: 90 degrees.
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NOTE:Make sure that new bolts are installed. Install the fuel injectors. - Tighten the bolts in two stages.
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Install the timing belt rear cover. | | | -
NOTE:Install a new fuel injection pump oil seal retainer. Install the fuel injection pump oil seal retainer. | | | -
Using sealant, seal the fuel injection pump pulley to the fuel injection pump sprocket. - Apply sealant to the outer edge of the fuel injection pump pulley bolt holes.
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Install the fuel injection pump pulley. | | | -
Using the special tool, install the camshaft oil seal. | | | -
NOTE:Do not fully tighten the camshaft pulley retaining bolt at this stage. Install the camshaft pulley retaining bolt. | | | -
Install the special tool. | | | -
Install the special tool. | | | -
NOTE:Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft to top dead center (TDC). - Turn the crankshaft slowly until the crankshaft stops.
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CAUTION:Make sure that the crankshaft does not rotate during installation of the special tool. CAUTION:Make sure the crankshaft is at the TDC position before locking the special tool. CAUTION:Make sure that the special tool engages correctly. Using the special tool, lock the crankshaft in position. | | | -
NOTE:Use only latest level timing belts. These are identified by a laser etched Ford logo. Check the timing belt. | Engines with mechanical timing belt tensioner | | -
Install a new automatic timing belt tensioner. | All vehicles | | -
Check the timing belt tensioner. - Make sure that the tensioner pointer rotates clockwise freely.
- Arrow denotes counterclockwise rotation of tensioner.
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Rotate the timing belt tensioner adjustment arm clockwise to the 3 o'clock position. | | | -
NOTE:Do not fully tighten the timing belt tensioner retaining bolt at this stage. Install the timing belt tensioner. | | | -
CAUTION:Never install a used timing belt. CAUTION:Install the timing belt with the direction arrows in the direction of crankshaft rotation. NOTE:Install a new timing belt. Install the timing belt. | | | -
NOTE:The camshaft pulley must be able to turn freely on the camshaft taper. Tighten the camshaft pulley bolt finger tight and then loosen by one-half turn. | | | -
NOTE:Using an Allen key, maintain the tension on the timing belt until the timing belt tensioner bolt is tightened. Tension the timing belt. - Turn the timing belt tensioner adjustment arm counterclockwise to tension the timing belt slightly.
- The pointer must be positioned between the sides of the window.
- Tighten the timing belt tensioner retaining bolt.
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Using the special tool, tighten the camshaft pulley retaining bolt. | | | -
NOTE:Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft six revolutions. | | | -
Install the special tool. | | | -
NOTE:Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft to TDC. - Turn the crankshaft slowly until the crankshaft stops.
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CAUTION:Make sure that the crankshaft does not rotate during installation of the special tool. CAUTION:Make sure the crankshaft is in TDC position before locking the special tool. CAUTION:Make sure that the special tool engages correctly. Using the special tool, lock the crankshaft in position. | | | -
CAUTION:If the pointer is not visible in the timing belt tensioner window, the timing belt tensioning steps must be repeated. Check that the timing belt tensioner pointer is positioned in the window. | | | -
CAUTION:If the special tool cannot be installed, the timing belt tensioning steps must be repeated. Install the special tool. - If the special tool cannot be installed, repeat procedure in previous steps.
| Vehicles with charge air cooler | | -
Install the engine front mount bracket. | | | -
Install the timing belt cover. | Vehicles without charge air cooler | | -
Install the engine front mount bracket. | | | -
Install the timing belt lower cover. | All vehicles | | -
NOTE:Install a new valve cover gasket if necessary. Install the valve cover. - Lubricate the valve cover gasket with engine oil before installation.
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Install the generator bracket. | | | -
NOTE:Install a new oil cooler gasket. Install the oil cooler. | | | -
NOTE:Install a new oil filter. Install the oil filter. | | | -
NOTE:Install new turbocharger oil supply line O-ring seals. Install the turbocharger oil supply line. | | | -
NOTE:Install a new turbocharger oil supply line O-ring seal. Attach the turbocharger oil supply line to the turbocharger. | | | -
Install the generator and drive shaft. | | | -
NOTE:Install new high pressure fuel supply lines. Install the high pressure fuel supply lines. | | | -
NOTE:Secure the oil separator to the engine lifting eye. Tighten the engine lifting eye and then tighten the oil separator. NOTE:Install the clip at a 45 degree angle to the horizontal. Attach the crankcase ventilation oil separator. | |
