Assembly

1. Install the upper crankshaft main bearings in the cylinder block.
- The third bearing from the front of the engine is the thrust bearing.

2. Install the lower crankshaft main bearings in the bearing caps.
- The third bearing from the front of the engine is the thrust bearing.

3. Install the crankshaft.
- Lubricate the main bearings and crankshaft journals with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A

NOTE: Make sure the Woodruff key is installed in the end of the crankshaft.

4. Clean the mating surfaces on the rear main bearing cap and the cylinder block.
- Use Metal Surface Cleaner F4AZ-19A536-AA or equivalent meeting Ford specification WSE-MSB392-A.
- Apply a small amount of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 in the location shown in the illustration.

NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with solvent. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

5. Install the main bearing caps.
- Arrows on the bearing caps indicate installation direction and location.
- Tighten the 2 bolts and 6 stud bolts in two stages.
* Stage 1: 50 Nm (37 ft. lbs.)
* Stage 2: 115-125 degrees

6. Install the camshaft.
- Lubricate the camshaft bearings, lobes and journals with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

7. Install the engine dynamic balance shaft.
- Lubricate the balance shaft bearings with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

8. Install the timing chain vibration damper.

9. Install the balance shaft drive gear.
- Timing marks on the balance shaft drive gear and driven gear must align.

10. Install the crankshaft sprocket, camshaft sprocket and timing chain as an assembly.
- Timing marks on gears and keyways on shafts must align.

11. Install the synchronizer drive gear.

12. Install the bearings in the piston connecting rod and rod cap.
- Lubricate the connecting rod bearings and crankshaft journals with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
- Lubricate the cylinder walls with clean engine oil and install the pistons. The arrow on the top of the piston must face the front of Me engine and the notches in the bearing shells must align.

13. Turn the crankshaft to position the number one piston at Top Dead Center (TDC). Crankshaft must not be turned until camshaft synchronizer is installed.

NOTE: All timing marks must be aligned with the number one piston at TDC.

14. Install the engine timing cover.
- Use a new gasket.

15. Install the water pump.
- Use a new gasket.

16. Install the oil baffle assembly.

17. Install the oil pump screen cover and tube.
- Use a new gasket.

18. Clean mating surfaces on oil pan and cylinder head.
- Use Metal Surface Cleaner F4AZ-19A536-AA or equivalent meeting Ford specification WSE-MSB392-A.
- Apply a bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 as shown in the illustration.

NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with solvent. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

19. Install the rear seal and oil pan.
- Tighten the bolts in two stages in the sequence shown.
* Stage 1: 4-5 Nm (36-44 lbs. inch)
* Stage 2: 9-12 Nm (80-106 lbs. inch)

20. Install a new O-ring on the synchronizer and make sure the oil pump intermediate shaft is installed with the lock ring in the synchronizer shaft.

21. Install the synchronizer, remove the alignment tool and install the camshaft position sensor.

NOTE: The arrow on the alignment tool must point as shown in the illustration. Make sure piston number one is at top dead center of the compression stroke.

22. Install the water bypass hose.
- Use a new O-ring.

23. Install the valve tappets and tappet guides.
- Lubricate the tappet bore and tappet roller with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

24. Install the cylinder heads.
- Use new gaskets and bolts.
- Tighten the bolts in three stages in the sequence shown:
* Stage 1: 20 Nm (14 ft. lbs.)
* Stage 2: 40 Nm (29 ft. lbs.)
* Stage 3: 50 Nm (36 ft. lbs.)

25. In the sequence shown, loosen the bolt three turns, then tighten the (A) short bolt or (B) long bolt to the specification indicated, and then further tighten the bolt to the (C) degrees indicated.

CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened and the final tightening completed prior to working on the next bolt in the sequence.

26. Install the rocker arms, rocker ann seats and push rods in the following positions:
- Number 1 - intake and exhaust
- Number 2 - exhaust
- Number 3 - intake
- Number 4 - exhaust
- Number 6 - intake

NOTE: Lubricate the ends of the push rods and rocker arm seats with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-hI99C80-A.