Part 1 of 2
NOTE: Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.1. Lubricate and install the crankshaft main bearings into the cylinder block. Install the crankshaft main bearings into the main bearing caps. Use clean engine oil meeting Ford specification WSS-M2C153-F.
2. Install crankshaft into the cylinder block.
CAUTION: Make sure coated side of thrust washer with three 5 mm wide oil grooves faces the crankshaft thrust surface.
3. Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.
4. Loosely install the main caps and bolts.
5. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.
6. Push the No. 5 main cap rearward and tighten.
NOTE: Make sure to tighten the bolts in four steps and in sequence shown.
7. Tighten the bolts 1 thru 20 in the sequence shown.
8. Tighten the bolts 1 thru 10 in the sequence shown.
9. Tighten the bolts 11 thru 20 in the sequence shown.
10. Tighten the bolts 1 thru 20 in the sequence shown.
11. Turn the ten jack screws until fully seated in the main bearing cap.
12. Tighten the jack screws in the sequence shown.
13. Install and tighten the cross-mounted bolts.
14. Check the crankshaft end play.
15. Rotate the crankshaft to make sure it turns freely.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: Make sure the piston notch is facing forward.
16. Use the Connecting Rod Guide and the Piston Ring Compressor to install the piston and connecting rod assembly.
- Lubricate the piston and ring with engine oil.
- Lubricate the rod bearings with engine oil.
- Check ring orientation.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: Make sure the crankshaft is at T.D.C.
17. Remove the Connecting Rod Guide when the connecting rod is seated on the crankshaft journal.
18. Install No. 1 and 6 pistons, rod and caps. Install bolts.
19. Tighten the bolts in the sequence shown.
20. To install No. 3 and 5, 4 and 7, 2 and 8, turn the crankshaft 90 degrees and repeat steps 18 and 19.
21. Measure the connecting rod clearance.
22. Apply silicone around the rear oil seal retainer sealing surface. Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
23. Install the crankshaft rear oil seal and retainer (6K301) and loosely install the bolts.
24. Tighten the six bolts in the sequence shown.
25. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal.
26. With the Rear Crankshaft Seal Adapter still installed, use the Rear (crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the crankshaft oil slinger.
27. Install and tighten the oil pump screen and cover spacer.
28. Position the oil pump and install the bolts in the sequence shown.
NOTE: Check O-ring on the oil pump pick up tube for tears or damage.
29. Install oil pump screen cover and tube and install the bolts for the oil pump screen and cover.
30. Install the oil filter adapter and the oil filter adapter gasket (6840) and install the bolts for the oil filter adapter in the sequence shown.
31. Install the oil bypass filter.
32. Apply Silicone and Gasket Sealant to the parting lines. Install the oil pan and the oil pan gasket. Loosely install the 12 bolts for the oil pan.
33. Tighten the bolts for the oil pan in the sequence shown.
34. Install and tighten the knock sensors (KS).
35. Install the head gaskets (6051).
CAUTION: Make sure the crankshaft and the camshaft are positioned properly to prevent piston crown and valve damage.
36. Position the crankshaft and the camshaft as shown.
37. Install the LH cylinder head and the RH cylinder head. Loosely install new bolts.
NOTE: Make sure to tighten the bolts in six steps.
38. Tighten the RH bolts in the sequence shown.
39. Tighten the RH bolts again in the sequence shown.
40. Loosen the RH bolts a minimum of one full turn (360°).
41. Tighten the RH bolts in the sequence shown.
42. Tighten the RH bolts again in the sequence shown.
43. Tighten the RH bolts in the sequence shown.
NOTE: Make sure to tighten the bolts in six steps.
44. Tighten the LH bolts in the sequence shown.
45. Tighten the LH bolts in the sequence shown.
46. Loosen the LH bolts a minimum of one full turn (360°).
47. Tighten the LH bolts in the sequence shown.
48. Tighten the LH bolts in the sequence shown.
49. Tighten the LH bolts again in the sequence shown.
50. Install the heater water hose and connect to the water bypass tube.
51. Install the bolts to the rear of the cylinder head.
52. Install the RH and the LH timing chain guide.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
Fig. 26 Crankshaft Sprocket Position:
53. Install the timing chain and crankshaft sprockets and make sure that the RH timing chain gear is in front of the LH timing chain gear with the hubs facing each other.
Fig. 25 Crankshaft To Camshaft Timing:
54. Check that the copper links on the timing chain/belts are lined up with the corresponding dots on the timing chain gears.
55. Check that the keyway on the camshafts sprocket are 90° from the camshaft cover surface.
56. Install the RH and the LH timing chain tensioner arm.
57. Install the RH and the LH timing chain tensioner.
58. Remove pins from tensioner.
59. Tighten the camshaft sprocket bolts.
60. Apply silicone along the head to block surface and to oil pan (6 places).
61. Install the crankshaft position sensor (CKP) pulse wheel with hub facing crankshaft sprockets.
62. Install the engine front cover on the dowel pins on the front of the cylinder block.
NOTE: Studs 1, 6 and 7 are shorter than studs 11-15.
63. Install the engine front cover. Loosely install the bolts and studs.
64. Tighten the bolts in the sequence shown.
65. Install and tighten the bolts in two steps.