Step 1-40

Engine



















Engine Induction System











Engine - Front End and Lower End











Engine - Flexplate and Engine Lubrication











Engine - Upper End













Assembly

All engines

1. Record the main bearing code found on the front of the engine block.





2. Record the main bearing code found on the back of the crankshaft.





3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart determine the required bearing grade for each main bearing.
- Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.

- Read down the column below the engine main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 1 crankshaft main bearing.

- As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is "2."

- Repeat this process for the remaining 4 main bearings.





4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing.





5. 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 with clean engine oil and install the crankshaft upper main bearings into the cylinder block.

6. Install the crankshaft onto the upper crankshaft thrust bearing and main bearings.





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

NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).

Install the rear main bearing cap.





8. Install the crankshaft lower main bearings, thrust bearing and thrust washer into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or dead-blow hammer.





9. NOTE: The jackscrews are a part of the main bearing cap assembly and are screwed into the main caps, not the cylinder block.

Back out the 10 jackscrews against the cylinder block in 2 stages, in the sequence shown.

- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 10 Nm (89 lb-in).





10. Install the 10 main bearing cap bolts and tighten in 2 stages, in the sequence shown.
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 21 Nm (15 lb-ft).





11. Tighten the 10 main bearing cap bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





12. Assemble the 8 pistons. For additional information, refer to Piston Piston - Disassembly And Assembly.

13. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.





14. Make sure the dimple in the piston faces the front of the engine.





15. Check piston-to-cylinder block and ring clearances. For additional information, refer to Engine System - General Information Piston To Cylinder Bore Clearance Piston Ring-To-Groove Clearance.

16. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine failure may occur.

NOTE: Make sure the piston arrow is facing forward.

NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.

Use the Piston Ring Compressor and Connecting Rod Installer to install the piston and connecting rod assemblies.

- Lubricate the piston and ring with clean engine oil.

- Lubricate the rod bearings with clean engine oil.

- Rotate the crankshaft as necessary.





17. NOTICE: 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 Installer.





18. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

NOTE: The connecting rod caps have a cracked design and must make mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod bearing cap, and install the 2 new bolts loosely.





19. Tighten the 16 connecting rod bearing cap bolts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 23 Nm (17 lb-ft).

- Stage 2: Tighten to 43 Nm (32 lb-ft).

- Stage 3: Rotate an additional 90-120 degrees.





20. Position the oil pump and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





Both cylinder heads

21. NOTE: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Head Cylinder Head - Removal.

NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

NOTE: The new gasket has a film coating which is crucial to the gasket's ability to seat correctly. Do not scratch the gasket.

NOTE: RH head gasket shown, LH head gasket similar.

Install the head gaskets over the dowel pins.





22. NOTE: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.

NOTE: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Head Cylinder Head - Removal.

NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

NOTE: Do not allow the dowels to scratch the sealing of the cylinder head during cylinder head installation.

NOTE: RH cylinder head shown, LH cylinder head similar.

Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.





23. Tighten the 10 cylinder head bolts in 6 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Tighten an additional 90 degrees (one-fourth turn).

- Stage 3: Loosen a minimum of one full turn (360 degrees).

- Stage 4: Tighten to 40 Nm (30 lb-ft).

- Stage 5: Tighten an additional 90 degrees (one-fourth turn).

- Stage 6: Tighten an additional 90 degrees (one-fourth turn).





24. Remove the Cylinder Head Remover/Installer from both ends of the cylinder head.





25. NOTE: Lubricate the O-ring seal with clean engine oil.

Install a new O-ring seal on the oil level indicator tube and install the oil level indicator tube and bolt.

- Tighten to 10 Nm (89 lb-in).





26. Install the new 8 LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).

27. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 new nuts.
- Tighten to 20 Nm (177 lb-in) in the sequence shown.





28. Install the new 8 RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).

29. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 new nuts.
- Tighten to 20 Nm (177 lb-in) in the sequence shown.





Engines with ratcheting timing chain tensioners

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

NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using an edge or a vise.





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





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





33. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
- Remove the tensioner from the vise.





Engines with non-ratcheting timing chain tensioners

34. NOTICE: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.

Inspect the RH and LH timing chain tensioners.

- Install new tensioners as necessary.

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

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using a vise.





36. Install a Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.





All engines

37. If the colored links are not visible, mark one link on one end and one link on the other end, and use as timing marks.





38. Using the Crankshaft Holding Tool, position the crankshaft.
- Remove the Crankshaft Holding Tool after crankshaft positioning.





39. Install the crankshaft sprocket, making sure the flange faces forward.





40. Install the timing chain guides.

1. Position the LH timing chain guide.

2. Install and tighten the 2 LH bolts to 10 Nm (89 lb-in).

3. Position the RH timing chain guide.

4. Install and tighten the 2 RH bolts to 10 Nm (89 lb-in).