Part 1 of 2

Special Tools:

1. Install the anti-drainback check ball.

2. Install the spring.

3. Install the anti-drainback check ball retainer cap.

4. NOTE: All eight piston oil cooling jets are installed the same way. Only one jet is shown.

Install the piston oil cooling jets.
1. Install the cooling jet.
2. Install the bolts.

5. NOTE: Coat the main bearing halves with Ford Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A after installing them into the bearing bores.

Install the upper halves of the main bearing into the bearing bores.

6. Install the crankshaft into the cylinder block.

7. NOTE: Do not turn the crankshaft while performing the main bearing clearance check.

Install the Plastigage(R).
1. Install the lower main bearing halves into the main bearing caps.
2. Place a piece of Plastigage(R) in the center of each main bearing journal on the crankshaft, and install the main bearing caps.
3. Tighten the main bearing cap bolts to specification.

8. Remove the main bearing caps and measure the clearance. Replace the main bearing if not within specification.

9. NOTE: Coat the main bearing halves with Ford Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

Install the main bearing caps.
1. Position the main bearing caps.
2. Install the bolts.

10. Tighten the main bearing cap bolts in the order shown.

11. Final tighten the main bearing cap bolts in the order shown.

12. NOTE: All eight piston and connecting rods are installed into the cylinder block the same way. Only one piston and connecting rod is shown.

Install the piston and rod assemblies.
1. Insert the piston into the Piston Ring Compressor. Position the piston, connecting rod and Piston Ring Compressor into the proper cylinder bore.
2. Coat the inside diameter of the ring compressor with clean engine oil. Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.

13. NOTE: Do not turn the crankshaft while performing the rod bearing clearance check.

NOTE: All eight rod bearings are checked the same way. Only one rod bearing is shown.

Check the rod bearing clearance.
1. Insert the upper rod bearing half into the connecting rod. Install the lower rod bearing half into the rod cap.
2. Place a piece of Plastigage(R) in the center of the rod bearing journal on the crankshaft. Install the connecting rod cap and nuts.

14. Remove the rod bearing cap and measure the clearance. Replace the rod bearing if not within specification.

15. NOTE: All eight connecting rod caps are installed the same way. Only one rod cap is shown.

Install the connecting rod cap.
1. Coat the connecting rod bearing half with Ford Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Position the connecting rod cap onto the connecting rod and seat the cap onto the crankshaft journal.
2. Install the nuts.
3. Final tighten the nuts.

16. NOTE: Thoroughly coat the camshaft bearing journals with Ford Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installing the camshaft into the engine block.

Install the camshaft.
1. Gently insert the camshaft into the engine block.

2. NOTE: It may be necessary to rotate the camshaft during installation to aid in inserting the camshaft through the camshaft bearings.

Before seating the camshaft drive gear with the crankshaft driven gear, rotate the crankshaft driven gear until the timing mark is in the 12 o'clock position. Align the timing mark on the camshaft drive gear with the timing mark on the crankshaft driven gear. Seat the camshaft drive gear with the crankshaft driven gear.
3. Install the two camshaft retaining bolts.

17. NOTE: All sixteen lifters are installed the same way. Only two lifters are shown.

NOTE: Before installing the lifters into the lifter bores, thoroughly coat the lifters using Ford Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C8O-A.

Install the lifters.
1. Insert the lifters into the lifter bores.
2. Install the retainer plate.
3. Install the retaining bolt.

18. CAUTION: Use caution when installing the engine rear cover. If the cover is bent, engine oil leaks will occur.

CAUTION: Use care not to use too much RTV sealant on the engine rear cover. Too much sealant can cause engine oil contamination and engine failure.

NOTE: The engine rear cover must be installed within three minutes after applying the RTV sealant to it. If the cover is not installed within three minutes, the RTV sealant must be removed and a new bead of RTV sealant must be applied.

Install the engine rear cover.
1. Apply a bead of RTV Silicone Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2.

Position the engine rear cover and install the bolts finger tight.
2. Tighten the bolts.

19. NOTE: The engine front cover must be installed within three minutes after applying the RTV sealant to it. If the cover is not installed within three minutes, the RTV sealant must be removed and a new bead of RTV sealant must be applied.

Install the engine front cover gasket.
1. Apply the RTV Silicone Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2, to the engine front cover.
2. Install the engine front cover gaskets.

20. Install the engine front cover.
1. Position the engine front cover onto the engine block.
2. Install the bolts.

21. Install the oil pickup tube gasket.
1. Apply a small amount of RTV Silicone Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2, to the engine front cover.
2. Install the gasket.

22. Install the oil pickup tube.
1. Position the oil pickup tube and install the bolts.
2. Install the nut.

23. NOTE: The oil pan must be installed within three minutes after applying the RTV sealant. If the oil pan is not installed within three minutes, the RTV sealant must be removed and a new bead of RTV sealant must be applied.

Apply RTV Silicone Sealant F5TZ-19G204-AB or equivalent meeting Navistar specification D15-5012 Type 2, to the oil pan.
1. Apply a bead of sealant.
2. Apply a bead of sealant.

24. Install the oil pan.
1. Position the oil pan.
2. Install the oil pan bolts.

25. NOTE: Both the left and the right engine mounts are installed the same way. Only the left side is shown.

Install the engine mounts.
1. Position the engine mounts.
2. Install the three bolts.

26. NOTE: The outer gerotor gear must be installed into the oil pump housing before the oil pump is installed onto the engine front cover.

Install the oil pump inner gerotor.

27. Install the oil pump.
1. With a new 0-ring, position the oil pump body plate onto the engine front cover.
2. Install the four bolts.

28. Install the crankshaft vibration damper.
1. Using a Damper Remover/ Replacer Tool, install the vibration damper onto the crankshaft.
2. Install the vibration damper bolt.

29. Install the Camshaft position (CMP) sensor.
1. Install the sensor into the engine front cover.
2. Install the sensor retaining bracket.
3. Install the bolt.

30. Install the exhaust back pressure sensor and tube.
1. Position the sensor and tube.
2. Install the nut.

31. Install the high pressure oil pump.
1. With a new gasket, position the high pressure oil pump.
2. Install the bolts.

32. CAUTION: Make sure that the drive gear is fully seated on the high-pressure oil pump before installing the bolt and washer. Otherwise, the drive gear may not seat properly, causing binding or slippage resulting in a no oil flow condition.

Install the high pressure oil pump drive gear.
^ Position the drive gear onto the high pressure oil pump. Install the bolt and washer.

33. Check the high pressure oil pump drive gear backlash.
1. Position the Dial Indicator with Bracketry onto the drive gear.
2. Rock the drive gear and record the reading.
^ Replace the drive gear if not within specification.

34. Install the gasket onto the engine front cover.

35. Install the high pressure oil pump reservoir.
1. Position the reservoir onto the engine front cover.
2. Install the bolts.