Part 1 of 2

1. Use Camshaft Bearing Set to install the camshaft bearings.
- Lubricate with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G.

CAUTION: The oil pump must be primed before the engine is started or engine damage could occur.

NOTE: Before engine assembly, use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A to clean the sealing surfaces. All sealing surfaces must be clean.

2. Install the crankshaft main bearings in the cylinder block.
- Lubricate the crankshaft main bearings using Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G.

3. Install the crankshaft main bearings in the crankshaft main bearing caps.
- Lubricate the crankshaft main bearings using Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G.





4. Position the crankshaft into the cylinder block.





5. Clean the rear main bearing cap sealing area thoroughly and apply sealant to the rear main bearing cap to cylinder block prating line.
- Use Metal Parts Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A.
- Use Pipe Sealant with Teflon (TM) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A.

NOTE:
- The crankshaft main bearings are precision selective fit. Inspect bearing clearance.
- If the rear main bearing cap is not installed within seven minutes, remove the sealant and reapply.





6. Install the main bearing caps and start the bolts.





7. Seat the thrust bearing while tightening the main bearing caps.





8. Tighten the bolts.
9. Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G to lubricate the piston rings.
10. Make sure the piston rings are properly spaced.





11. Use Piston Ring Compressor to install the pistons into the cylinder block.

NOTE: Position the pistons with the arrow in the piston head pointing toward the front of the cylinder block.

12. Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G to lubricate the connecting rod bearings.
13. Check the clearance of each connecting rod bearing.

NOTE: The old connecting rod nuts and bolts are used for checking clearances. New connecting rod nuts and bolts must be used for reassembly.

14. Rotate the crankshaft until the piston is at the bottom of the stroke.





15. Loosen the first connecting rod nut until the face is approximately 2 mm over the end of the bolt.

NOTE: For cylinders 1, 2 and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5 and 6, remove the opposite connecting rod nut first.





16. Tap the connecting rod nut, until the bolt can be removed by hand.
17. Repeat Steps 15 and 16 for the opposite bolt.





18. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.
19. Install the connecting rod cap in the original position.





20. Install the connecting rod nuts until they touch the connecting surface of the connecting rod cap.

NOTE: Do not exceed 20 Nm at this time when tightening the connecting rod nuts.





21. Tighten the connecting rod nuts in pairs in two steps:
- Step 1: Tighten to 20 Nm.
- Step 2: Tighten an additional 90 degrees.

22. Repeat Steps 15-21 for the remaining connecting rods.





23. Position the oil pump intermediate shaft in its Original position.

NOTE: Insert oil pump intermediate shaft into cylinder block with the pointed end facing inward. The pointed end is closest to the pressed-on flange.





24. Position the oil pump and install the bolts.





25. Position the crankshaft oil baffle and install the nuts.





26. Lubricate the camshaft and install it into the cylinder block.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





27. Position the camshaft thrust plate and Install the bolts.





28. Install the timing chain guide and the bolts.








29. Install the timing chain.
1 Position the crankshaft main bearing thrust washer and camshaft sprocket on the timing chain while aligning the timing marks.
2 Install the bolt.





30. Position the timing chain tensioner and install the bolts.
31. Lubricate the timing chain and sprockets.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





32. Install the twelve valve tappets in the original position.

NOTE: Lubricate the valve tappets using Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C 153-G.





33. Position the LH cylinder head and gasket and tighten the bolts in three steps in the sequence shown:
- Step 1: Tighten to 30-35 Nm (22-26 ft. lbs.).
- Step 2: Tighten to 70-75 Nm (52-56 ft. lbs.).
- Step 3: Tighten an additional 90 degrees.

NOTE:
- The LH cylinder head is shown; the RH cylinder head is similar.
- New cylinder head bolts must be used.




34. Install the RH push rods in their original position.





35. Position the RH rocker arm shaft and install the bolts in two steps:
- Step 1: Tighten to 32 Nm.
- Step 2: Tighten an additional 90 degrees.





36. Install the LH push rods in their original position.





37. Position the LH rocker arm shaft and install the bolts in two steps.
- Step 1: Tighten to 32 Nm.
- Step 2: Tighten an additional 90 degrees.

38. Install the engine front cover gasket to the engine front cover.





39. Position the engine front cover and install the studs.





40. Install the bolts.





41. Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to lubricate the engine front cover surface and the front oil seal inner lip.





42. Use Crankshaft Seal Replacer/Cover Aligner to install the front oil seal into the engine front cover.
43. Install the oil pan gasket to the oil pan.





44. Position the oil pan and install the nuts.





45. Install the oil pan bolts.
46. Install the water pump housing gasket to the water pump.





47. Position the water pump and install the stud bolts.





48. Install the bolts.
49. Position the lower intake manifold gasket





50. Position the lower intake manifold and install the bolts in three steps:
- Step 1: Tighten to 8 Nm (71 lb/in).
- Step 2: Tighten to 12 Nm (107 lb/in).
- Step 3: Tighten to 16 Nm (143 lb/in).





51. Position the oil filter adapter and install the bolt.