Part 1 of 2

NOTE: Before engine assembly, use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

1. Install the crankshaft and camshaft bearings.
^ Lubricate and install the crankshaft main bearings in the crankshaft main caps.
- Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.

^ Lubricate and install the crankshaft main bearings in the cylinder block.
- Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.

^ Lubricate the camshaft bearings and use Camshaft Bearing Set to install the camshaft bearings.
- Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.





2. Position the crankshaft.





3. Clean the rear main bearing cap sealing area thoroughly and apply sealant to the rear main bearing cap to cylinder block prating line.
^ Use Metal Parts Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

NOTE: The main bearings are precision selective fit. Inspect the bearing clearance. If the rear main bearing cap is not installed within four minutes, remove the sealant and reapply.





4. Install the rear main bearing cap and start the bolts.

NOTE: Use a straight edge to ensure that the rear main bearing cap is flush with the rear face of the cylinder block.





5. Install the main bearing caps and start the bolts.





6. Seat the thrust bearing while tightening the main bearing caps.





7. Torque the main bearing cap bolts.





8. Lubricate the crankshaft rear oil seal and crankshaft sealing surface.
^ Use Motorcraft Super Premium 10w-30 Motor Oil XO-lOW30-QSP or equivalent meeting Ford specification ESE-M2C153-E and API SG.





9. Position Rear Crank Adapter and install the crankshaft rear oil seal using Rear Crank Seal Replacer Spacer and Rear Crank Seal Replacer.

NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use extra-fine emery cloth or extra-fine 0000 steel wool with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A.





10. Check that the crankshaft rear main seal is within specification.
11. Lubricate the cylinder bores.
^ Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.

12. Ensure that the piston rings are properly spaced.





13. Use Piston Ring Compressor to install the piston.

NOTE: Position the piston with the identification notch in the piston head toward the front of the engine block.

14. Lubricate the connecting rod bearings.
^ Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.

15. Check the clearance of each connecting rod bearing.





16. Install the connecting rod cap and torque the nuts.





17. Lubricate the camshaft and install into the cylinder block.
^ Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.





18. Install the camshaft thrust plate.
a. Lubricate and position the camshaft thrust plate. Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.
b. Install and torque the camshaft thrust plate bolts.

NOTE: The oil groove must face the rear of the engine.





19. Position the crankshaft sprocket, camshaft sprocket and the timing chain while aligning the timing marks.





20. Install and torque the camshaft sprocket bolt.
21. Lubricate the timing chain and sprockets.
^ Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.





22. Position the lower engine front cover gasket and lower engine front cover and install the four lower engine front cover bolts.





23. Lubricate the engine front cover and front oil seal inner seal inner lip.
^ Use engine oil meeting Ford specification WSE-M2C908-A1.





24. Use Crankshaft Seal Replacer/Aligner to install the front oil seal into the engine front cover.





25. Apply silicone sealant 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.





26. Position the crankshaft pulley and torque the crankshaft vibration damper bolt.

NOTE: Use a suitable strap wrench to hold the crankshaft pulley.





27. Position the oil pump and install the oil pump bolts.





28. Install the oil pump screen cover and tube.
a. Install and torque the oil pump screen cover and tube nut.
b. Position the gasket and install and tighten the two oil pump screen cover and tube bolts.





29. Apply sealant in six positions.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

NOTE: The oil pan gasket must be installed within four minutes after applying the silicone.





30. Install the oil pan gasket.





31. Apply sealant in four positions.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

NOTE: The oil pan must be installed within four minutes after applying the silicone.





32. Position the oil pan and start the twenty-two oil pan bolts.
a. Tighten the four oil pan end bolts.
b. Tighten the eighteen oil pan bolts.





33. Install a new water pump gasket and the water pump.





34. Position the water pump pulley and install the four water pump pulley bolts.





35. Position the crankshaft position (CKP) sensor and timing pointer and install the two bolts.





36. Connect the oil cooler to the water inlet hose.





37. Position the oil cooler O-ring and install the oil cooler.





38. Install the oil cooler bolt and oil cooler bolt O-ring.

CAUTION: Be sure to position the oil cooler bolt O-ring into the groove on the oil cooler. Failure to properly position the O-ring may cause an engine oil leak. Coat the O-ring with petroleum jelly to hold the O-ring in place during oil cooler bolt installation.





39. Tighten the oil cooler bolt.





40. Position the head gasket over the two dowel pins.

NOTE: The RH is shown; the LH is similar. A specially treated composition gasket is used. Do not apply sealer to a composition gasket.

41. Install the cylinder head on the cylinder block gasket and install the ten new cylinder head bolts in three stages.
^ Stage 1: 34-47 Nm (25-35 ft. lbs.).
^ Stage 2: 61-75 Nm (45-55 ft. lbs.).
^ Stage 3: 85°-90°.

42. Lubricate the valve tappet bores before installing the valve tappets.
^ Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.





43. On early models, install the valve tappets and the valve tappet guide plates in their original positions.