Part 1 of 2

NOTE: Before engine assembly, use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

1. Install the crankshaft main bearings and camshaft bearings.
- Lubricate and install the crankshaft main bearings in the crankshaft main caps.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
- Lubricate and install the crankshaft main bearings in the cylinder block.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
- Lubricate the camshaft bearings and use Camshaft Bearing Set to install the camshaft bearings.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





2. Position the crankshaft.





3. 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-M5B392-A.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

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





4. Install the rear main bearing cap and start the bolts.

NOTE: Use a straight edge to make sure that the rear main bearing cap is flush with the rear face of the cylinder block.





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





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





7. Tighten the bolts.





8. Lubricate the crankshaft rear oil seal and crankshaft sealing surface.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





9. Position Rear Crank Adapter and install the crankshaft rear oil seal using Rear Crank Seal Replacer Spacer and Rear Crank Seal Replacer.

NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use extra-fine emery cloth or extra-fine 0000 steel wool with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A.





10. Check that the crankshaft rear oil seal is within specification.
11. Lubricate the cylinder bores.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

12. Make sure that the piston rings are properly spaced.





13. Use Piston Ring Compressor to install the piston.

NOTE: Position the piston with the identification notch in the piston head toward the front of the cylinder block.

14. .Lubricate the connecting rod bearings.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

15. Check the clearance of each connecting rod bearing.





16. Install the connecting rod cap and the nuts.





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





18. Install the camshaft thrust plate.
1 Lubricate and position the camshaft thrust plate. Use Super Premium SAE 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
2 Install the bolts.

NOTE: The oil groove must face the rear of the engine.





19. Position the crankshaft sprocket, camshaft sprocket and the timing chain/belt while aligning the timing marks.





20. Install the bolt.
21. Lubricate the timing chain/belt and sprockets.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





22. Position the lower engine front cover and engine front cover gasket and install the four bolts.





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





24. Use Crankshaft Seal Replacer/Aligner to install the crankshaft front seal into the engine front cover.





25. Apply silicone sealant to the woodruff key slot on the crankshaft pulley.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.





26. Position the crankshaft pulley and install the bolt.

NOTE: Use a suitable strap wrench to hold the crankshaft pulley.





27. Position the oil pump and install the bolts.





28. Install the oil pump screen cover and tube.
1 Install the nut.
2 Position the gasket and install the bolts.





29. Apply sealant in six locations.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

NOTE: The oil pan gasket must be installed within four minutes after applying the silicone.





30. Install the oil pan gasket.





31. Apply sealant in four positions.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

NOTE: The oil pan must be installed within four minutes after applying the silicone.





32. Position the oil pan and install the twenty-two bolts.
1 Tighten the four end bolts.
2 Tighten the remaining eighteen bolts.





33. Install a new water pump housing gasket end the wafer pump.





34. Position the water pump pulley and install the bolts.





35. Position the Crankshaft Position Sensor (CKP sensor) and timing pointer and install the bolts.





36. Connect the oil cooler to the water inlet hose.





37. Position the oil cooler O-ring and install the oil cooler.





38. Install the bolt and the O-ring.

CAUTION: Be sure to position the O-ring into the groove on the oil cooler. Failure to properly position the O-ring may cause an engine oil leak. Coat the O-ring with petroleum Jelly to hold the O-ring in place during bolt installation.





39. Tighten the bolt.





40. Position the head gasket over the two dowel pins.

NOTE:
- The RH is shown; the LH is similar.
- A specially treated composition gasket is used. Do not apply sealer to a composition gasket.

CAUTION: This engine uses "Torque To Yield Bolts". Always use new cylinder head bolts to ensure leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface.