Assembly

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

Lubricate and install crankshaft main bearings into cylinder block. Install crankshaft main bearings and crankshaft thrust main bearing into main bearing caps.

2. Install crankshaft into cylinder block.











3. Push crankshaft rearward. Lubricate with clean engine oil meeting Ford specification ESE-M2C153-E and install upper crankshaft thrust washer, by rolling the crankshaft thrust washer onto machined shelf between rear side of No. 5 bulkhead and thrust face surface of crankshaft. Make sure coated side of crankshaft thrust washer with three 5 mm wide oil grooves is facing the crankshaft thrust surface.






4. NOTE: Crankshaft main bearing cap adjusting screws must be bottomed on main bearing cap prior to installation of main bearing cap.

Install main bearing caps. Tap main bearing caps with a brass hammer to seat caps properly.






5. Push crankshaft forward using a prybar or similar tool to seat crankshaft thrust main bearing and crankshaft thrust washer.

6. NOTE: No. 5 main bearing cap must be seated until the main bearing cap bolts are fully tightened as outlined below.

With crankshaft pushed forward, install pry bars or similar tools to push both RH and LH front edges of No. 5 main bearing cap rearward and position the lower crankshaft thrust main bearing rear face properly against the thrust face of the crankshaft.






7. CAUTION: Main bearing bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.

Tighten new main bearing cap bolts one through ten in two steps as follows:

a. Tighten bolts in sequence to 37-43 Nm (27-31lb-ft).
b. Rotate bolts in sequence 85-95°.

8. Tighten crankshaft main bearing cap adjusting screws in sequence to 9-11 Nm (80-97 lb-in).

9. Tighten main bearing cap side bolts in sequence to 19-23 Nm (14-16 lb-ft).






10. NOTE: Pry against number two main bearing cap.

Check crankshaft end play in both directions as shown.






11. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.Apply a 1.5 mm (0.06 inch) continuous bead of Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6 to cylinder block as shown.






12. Install crankshaft rear oil seal retainer to cylinder block and tighten six bolts in sequence to 8-12 Nm (71-106 lb-in).






13. Using Rear Crank Seal Replacer Adapters T91P-6701-A and Rear Main Seal Replacer T82L-6701-A, install crankshaft rear oil seal.

14. Coat piston bores, pistons, rings, crankshaft journal and bearing surfaces with clean engine oil meeting Ford specification ESE-M2C153-E.

15. NOTE: Make sure piston ring gaps are rotated 30° apart.

NOTE: Notch on piston to front of engine.

Turn crankshaft until the crankshaft throw is at bottom of stroke. Install correctly numbered pistons, connecting rods and upper connecting rod bearings with Piston Ring Compressor Tool D81L-6002-C or equivalent and a suitable connecting rod guide tool or equivalent.

16. CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod.











Push piston down until connecting rod bearing seats on crankshaft.

17. NOTE: Due to the use of a cracked connecting rod joint face surface, the connecting rod cap must be properly aligned to the connecting rod. The connecting rod and connecting rod cap bearing tangs should be located on the same side of the connecting rod.

Install connecting rod cap and lower connecting rod bearing and alternately tighten new connecting rod cap bolts in several passes to obtain 40-45 Nm (30-33 lb-in) and rotate connecting rod bolts an additional 90-120°. After installation, rotate crankshaft to ensure smooth operation.






18. Check connecting rod side clearance using Rotunda Dial Indicator with Bracketry TOOL-4201-C or equivalent. Clearance should be 0.15-0.45 mm (0.006-0.0177 inch). If side clearance is greater than maximum service limit of 0.50 mm (0.020 inch), replace connecting rods and/or crankshaft.

19. NOTE: Install new O-ring on oil pump screen cover and tube and then start all bolts on oil pump and oil pump screen cover and tube before tightening.











Install oil pump and oil pump screen cover and tube.

20. NOTE: Make sure cylinder heads are installed in their original positions.

If cylinder heads are to be serviced, refer to Subassemblies, Cylinder Head in Disassembly and Assembly.

21. CAUTION: Do not use sandpaper coarser than 600 grit. Damage to sealing surfaces may occur.

NOTE: Clean cylinder head gasket surface with a toluene-based paint thinner or gasket remover. If gasket material remains on head after cleaning, use a 600 grit sandpaper to remove remaining material.

NOTE: RH and LH head gaskets are not interchangeable.






Position new head gaskets on cylinder heads.

22. CAUTION: Failure to position crankshaft as shown will cause damage to pistons and/or valve train components.

NOTE: With crankshaft in this position, no piston will be at top dead center (TDC).






Rotate crankshaft to position as shown.

23. CAUTION: Use care when positioning cylinder heads. Damage to cylinder block and/or cylinder heads may result.






Position cylinder heads on cylinder block. Use Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A to prevent crankshafts from rotating.

24. CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.

NOTE: Apply clean engine oil meeting Ford specification ESE-M2C153-E to all head bolt spot-faces.






Tighten new cylinder head bolts as follows:

a. Tighten head bolts in sequence to 37-43 Nm (27-31 lb-ft).
b. Rotate head bolts in sequence 85-95°.
c. Loosen head bolts a minimum of one full turn (360°).
d. Retighten head bolts in sequence to 37-43 Nm (27-31 lb-ft)
e. Rotate head bolts in sequence 85-95°.
f. Rotate head bolts in sequence an additional 85-95°.

25. CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as top dead center (TDC) No. 1 cylinder.






Rotate crankshaft clockwise 45°. This will position crankshaft at top dead center (TDC) No. 1 cylinder.

26. Install timing chains as outlined.

27. Replace crankshaft front seal in engine front cover if required.











28. Install engine front cover as outlined.











29. Install oil pan with new oil pan gasket. Tighten bolts to 25-35 Nm (18-25 lb-ft) in no more than four minutes after applying sealer.

30. Lubricate water pump housing gasket with Ford Premium Cooling System Fluid E2FZ-19549-AA (in Canada, Motorcraft CXC-8-B) or equivalent meeting Ford specification ESE-M97B44-A and install water pump and tighten retaining bolts to 20-30 Nm (15-22 lb-ft).











31. Install heater water hose and EGR backpressure transducer bracket to LH cylinder head.











32. Install crankshaft position sensor (CKP sensor) and camshaft position sensors into engine front cover and tighten retaining bolts to 8-12 Nm (71-106 lb-in).






33. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.

NOTE: Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6 must be applied to crankshaft keyway prior to installing crankshaft pulley.

Install crankshaft pulley using Crankshaft Damper Replacer T74P-6316-B.

34. Install crankshaft pulley bolt and crankshaft pulley retaining washer. Tighten to 155-165 Nm (114-121 lb-ft).











35. Install RH and LH valve cover gaskets. Tighten studs and bolts to 8-12 Nm (71-106 lb-in).

36. If intake manifold was disassembled, assemble as follows:

a. Install fuel injector O-rings on fuel injectors with clean engine oil meeting Ford specification ESE-M2C153-E prior to assembly.
b. Install fuel injection supply manifold and fuel injectors and tighten four bolts to 8-12 Nm (71-106 lb-in).
c. Install engine coolant temperature sensor and water temperature indicator sender unit and gasket, then tighten to 16-24 Nm (12-17 lb-ft).
d. Install idle air control valve and gasket. Tighten bolts to 8-12 Nm (71-106 lb-in).
e. Install throttle body and throttle body adapter. Tighten bolts to 8-12 Nm (71-106 lb-in).

37. NOTE: Inspect intake manifold gasket and replace if necessary. Align tabs on intake manifold gasket with holes in cylinder heads.

Position intake manifold gasket on cylinder heads.

38. Install intake manifold as outlined. Tighten retaining bolts in sequence to 20-30 Nm (15-22 lb-ft).

39. NOTE: Water outlet connection bolts are also intake manifold retaining bolts.

Install water outlet connection O-ring and water hose connection. Tighten bolts to 20-30 Nm (15-22 lb-ft).

40. NOTE: Inspect oil filter adapter gasket, replace if necessary.

Install oil filter adapter and tighten bolts to 20-30 Nm (15-22 lb-ft).











41. Install oil bypass filter.

42. Install LH exhaust manifold and tighten bolts to 20-30 Nm (15-22 lb-ft).

43. Install RH exhaust manifold and tighten bolts to 20-30 Nm (15-22 lb-ft).

44. Install drive belt idler pulley and drive belt tensioner with ignition coils and tighten seven nuts to 20-30 Nm (15-22 lb-ft).






45. Install A/C compressor and tighten three bolts to 20-30 Nm (15-22 lb-ft).

46. Install water pump pulley and tighten bolts to 20-30 Nm (15-22 lb-ft).

47. Install generator and tighten generator-to-cylinder block retaining bolts to 20-30 Nm (15-22 lb-ft).

48. Install generator mounting bracket and tighten to 8-12 Nm (71-106 lb-in).

49. Install positive crankcase ventilation valve and front vapor hose.

50. Install flywheel to crankshaft and tighten six bolts to 73-87 Nm (54-64 lb-ft).

51. Install engine control sensor extension wire and connect all applicable wiring connectors.











Fuel Charging Wiring

52. Install spark plugs. Tighten to 9-20 Nm (7-14 lb-ft).

53. Install ignition wires.