I have the heads off the engine and I thought I would actually see if the crank shaft positioning sensor put #1 at TDC _ well it doesn't.
With everything out of the way, there is an additional timing mark on the front of the timing chain cover.
The green arrow is pointing to it, I had to shine the light behind it to get a decent photo, so you're actually looking at the shadow of the new found timing mark.
The red arrow is pointing to the small protrusion indicating that this is the actual mark for TDC and not the crank shaft position sensor.
I can confirm this easily with the heads off as I can tell that #1 is at TDC.
If I move the harmonic dampener to the CPS position as TDC, I can clearly see that the piston is no longer at TDC, it's about 15 degrees out from TDC.
The question is, which TDC mark to use when timing the cam shaft synchronizer and sensor ?
Everyone is using the CPS as TDC, but as I discovered, it's not actually TDC.
What's the Ford dealership using ?
Here's a better photo, the protrusion on the end of the timing mark can be seen too.