Assembly

Special Tools:

Special Tool:

Special Tools:

1. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear,

Lubricate and install the crankshaft upper main bearings into the cylinder block.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

2. Install the crankshaft into the cylinder block and onto the upper crankshaft main bearings.

3. Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.

4. Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.

5. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.

6. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and tap into place using a plastic or dead-blow hammer.

7. Install the bolts.

8. Install the ten dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.

9. Tighten fasteners 1 through 12 in two stages in the sequence shown.
^ Stage 1: Tighten to 37-43 Nm (22-32 ft. lbs.)
^ Stage 2: Tighten an additional 85 degrees to 95 degrees

10. Tighten fasteners 13 through 24 in two stages in the sequence shown.
^ Stage 1: Tighten to 27-33 Nm (20-26 ft. lbs.)
^ Stage 2: Tighten an additional 85 degrees to 95 degrees

11. Use the Connecting Rod Guide Tool and Piston Ring Compressor to install the piston and connecting rod assembly.

12. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Once the connecting rod is seated on the crankshaft journal, remove the connecting rod guide tools.

13. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated properly.

Install the connecting rod bearings, position the connecting rod cap and loosely install the two new bolts.

14. NOTE: Be sure to tighten the bolts in two stages.

Tighten the connecting rod bolts in the sequence shown.
^ Stage 1: Tighten to 40-45 Nm (30-33 ft. lbs.)
^ Stage 2: Tighten an additional 90 degrees to 120 degrees

15. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.

16. Install the oil filter adapter.
17. Install the front engine support insulators.

18. Install the lower crankshaft bearing supports and tighten fasteners in the sequence shown.

19. Install the oil level indicator tube.

20. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.

21. Rotate the crankshaft to position the keyway at 12 o'clock.

22. NOTE: Do not turn the crankshaft until instructed to do so.

Install the head gasket over the dowel pins.
23. Install the Camshaft Holding Tools.

24. Install the Lifting Handles.

25. Install the cylinder head on the head gasket and loosely install the bolts.
^ The LH is shown, the RH is similar.

26. NOTE: Be sure to tighten the bolts in three stages.

Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 37-43 Nm (27-32 ft. lbs.)
^ Stage 2: Tighten an additional 85 degrees to 95 degrees
^ Stage 3: Tighten an additional 85 degrees to 95 degrees

27. Install the left and right exhaust manifold gaskets and exhaust manifolds. Loosely install the nuts. Tighten the nuts in the sequence shown.

28. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

If removed, install the left and right camshaft sprockets.

29. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Compress the tensioner plunger, using an edge of a vise.

30. Using a small screwdriver or pick, push back and hold the ratchet mechanism.

31. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

32. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.

33. If the copper links are not visible, mark two links on one end and one link on the other end to use as timing marks.

34. Loosen the Camshaft Holding Tools on both camshafts).

35. Install the timing chain guides.

36. Rotate the LH camshaft sprocket until the timing mark is approximately at 12 o'clock.
Rotate the RH camshaft until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Holding Tools to maintain camshaft pre-positioning.

37. CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston or valve damage can occur.

Position the crankshaft with the Crankshaft Holding Tool.
38. Remove the Crankshaft Holding Tool.

39. Position the inner crankshaft sprocket with the long hub facing outward.

40. Install the LH timing chain/belt onto the crankshaft sprocket, aligning the one copper link on the timing chain/belt with the slot on the crankshaft sprocket.

41. NOTE: Make sure the upper half of the timing chain/belt is below the tensioner guide dowel. If necessary, use the Camshaft Holding Tool to adjust.

NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

Position the timing chain/belt on the camshaft sprocket with the two copper chain links and the camshaft sprocket timing mark aligned.

42. CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured.

NOTE: Be sure the copper chain link and crankshaft sprocket timing mark are aligned.

NOTE: The lower half of the timing chain/belt must be positioned above the dowel.

Position the outer camshaft sprocket and the RH timing chain/belt with the long hub of the camshaft sprocket facing inward.

43. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

Position the RH timing chain/belt on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark.

44. As a post-check, verify timing mark alignment.

45. Position the LH and RH timing chain tensioner arm on the dowel pins. Position the timing chain tensioners, and install the bolts.

46. Remove both the RH and LH retaining pins from the timing chain tensioner assembly.

47. Remove the Camshaft Holding Tools from the camshafts.
48. Lubricate the balance shaft journals with engine oil.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

49. Position the balance shaft on the journals.

50. Align the balance shaft timing marks as shown.

51. Install the bearing caps and the bolts. Tighten the bolts in the sequence shown.

52. Position the crankshaft sensor ring.

53. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. 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.

NOTE: The RH timing chain/belt is removed for clarity.

Apply a bead of silicone along the cylinder head-to-block surface and the oil pan-to-cylinder block surface.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

54. Install a new engine front cover gasket onto the engine front cover, then position the engine front cover on the front cover to cylinder block dowel.

Engine Front Cover Bolt Sequence:

55. Loosely install the fasteners.
56. Tighten the fasteners in two stages.
^ Stage 1: Tighten fasteners 1 through 7 to 20-30 Nm (15-22 ft. lbs.)
^ Stage 2: Tighten fasteners 6 through 15 to 40-55 Nm (30-41 ft. lbs.)

57. Position the oil pump screen cover and tube and install the bolts and nut.

58. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. 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.

Apply a bead of silicone where the rear crankshaft seal retainer plate and the front cover meets the cylinder block.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

59. NOTE: Be sure to tighten the bolts in three stages.

Install the oil pan. Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.)
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.)
^ Stage 3: Tighten an additional 60 degrees

60. Install the oil drain plug.

61. CAUTION: Do not rotate the water pump housing once the water pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Install the water pump.
1. Lubricate the new O-ring seal using Premium Cooling System Fluid E2FZ-19549-AA (in Canada CXC-10, in Oregon F5FZ-19549-CC) or equivalent meeting Ford specification ESE-M971344-A and install the O-ring seal onto the water pump.
2. Position the water pump into the cylinder block.
3. Install the water pump retaining bolts.

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

63. Use the (A) Crankshaft Seal Replacer/Aligner to install the (B) crankshaft front seal into the (C) engine front cover.

64. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. 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.

Apply silicone 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.

65. Use the Crankshaft Damper Replacer to install the crankshaft pulley.

66. Tighten the crankshaft pulley bolt in four stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 47-53 Nm (35-39 ft. lbs.).
^ Stage 4: Tighten an additional 85-90 degrees.

67. Position the water pump pulley on the water pump and install the bolts.

68. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. 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.

Apply silicone in two places where the engine front cover meets the cylinder head.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

69. Position the valve covers.

70. Tighten the bolts in the sequence shown.
71. Install the engine control wire harness.