Assembly

1. Clean the main bearing caps and the cylinder block saddles.
2. Install the bearings in the cylinder block and the main bearing caps.
3. Carefully position the crankshaft into the cylinder block.

CAUTION: Handle the crankshaft with care to avoid possible fracture or damage to the finished surfaces.

NOTE: Make sure the timing marks are lined up when installing the crankshaft.





4. Install the main bearing caps and bolts.
5. Remove the cylinder wall glaze if new piston rings are to be installed.
6. Oil the piston rings, piston and cylinder walls with specified engine oil.

CAUTION: Make sure to install pistons in the same cylinders from which they were removed or to which they were fitted. If a connecting rod is ever transposed from one cylinder block or cylinder to another, new connecting rod bearings must be fitted and the connecting rod must be numbered to correspond with a new cylinder number.





7. Make sure ring gaps are properly spaced around the circumference of the piston and position the piston rings as shown.
1 Position the oil control ring.
2 Position the second compression ring.
3 Position the first compression ring.

NOTE: Make sure the indentation marks on the top two compression rings are facing up.

8. Turn the crankshaft to the full down position.
9. Position the upper connecting rod bearing into the connecting rod and push piston down until the connecting rod bearing seats on the crankshaft journal. Remove the protective sleeves (rubber hose) and install the lower connecting rod bearing and connecting rod cap.

NOTE: Install the piston with the arrow on the piston head toward the camshaft.

10. Check the clearances of each connecting rod bearing and connecting rod side clearance.
11. Apply a light coat of specified engine oil to crankshaft journals and connecting rod bearings.





12. Install the connecting rod nuts.

NOTE: Lightly coat the connecting rod bolt threads with oil before installing.

13. Clean the nose of the camshaft and install the camshaft thrust plate onto the camshaft.
14. Position the camshaft sprocket key in the keyway on the camshaft.
15. Heat the camshaft drive gear in an oven at 260°C (500°F).





16. Remove the camshaft sprocket from the oven and, while aligning the sprocket keyway with the camshaft sprocket key, install the camshaft sprocket over the nose of the camshaft until fully seated against the camshaft thrust plate journal. Allow the camshaft assembly to cool before installing into the engine.

WARNING: WEAR PROTECTIVE GLOVES TO HANDLE HOT GEARS. FAILURE TO DO SO WILL CAUSE SEVERE PERSONAL INJURY.

CAUTION: The gear will be permanently distorted if overheated. The oven temperature must never exceed 260°C (500°F).





17. Carefully slide the camshaft, with the camshaft sprocket and camshaft thrust plate, down into the camshaft bearings. Make sure the camshaft sprocket and crankshaft sprocket timing marks are properly aligned after the camshaft is installed.

NOTE: Before installing, coat the camshaft lobes with Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESR-M1C159-A and ESB-M1C93-A. Lubricate the camshaft journals with engine oil specified for this engine.





18. Install the camshaft thrust plate retaining bolts.
19. Install the valve tappets.





20. Install the two new engine timing cover gaskets and apply RTV Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2 to the sealing grooves in the engine timing cover.

NOTE: Silicone rubber sealant (RTV) starts to set up after being exposed to the air. Assembly must be completed within 10 minutes of sealant application.





21. Install the engine timing cover and the retaining bolts.





22. Install the inner gerotor on the crankshaft.





23. Assemble the oil pump body plate, outer gerotor and O-ring. Liberally apply oil to gerotor pump.





24. Install the oil pump housing and bolts.





25. Install the crankshaft vibration damper and bolt.
26. Install the high-pressure oil pump oil reservoir.
27. Install the water pump.





28. Install the oil pump inlet tube gasket on the oil pump screen cover and tube mounting flange. Use a small amount of RTV Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2 to hold the oil pump inlet tube gasket in place, if necessary.

CAUTION: Do not apply excessive amounts of RTV. Excess sealant can enter into the oil lubrication system and cause a restriction.





29. Install the oil pump screen cover, tube and the retaining nuts and screws.





30. Apply RTV sealant as specified.
1 Apply a 3.2-mm (1/8-inch) bead of RTV Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2.
2 Apply a 6.35-mm (1/4-inch) bead of RTV Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2.

CAUTION: Do not apply excessive amounts of RTV. Excess sealant can enter into the oil lubrication system and cause a restriction.

NOTE: Install the oil pan and retaining bolts within 10 minutes of applying RTV sealant.





31. Install the oil pan and retaining bolts.
32. Install the engine.