Assembly

Special Tools:

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 main bearings and camshaft bearings.
^ Lubricate and install the crankshaft main bearings in the crankshaft main caps.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
^ Lubricate and install the crankshaft main bearings in the cylinder block.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
^ Lubricate the camshaft bearings and use Camshaft Bearing Set to install the camshaft bearings.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





2. Position the crankshaft.





3. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance.

NOTE: If the rear main bearing cap is not installed within four minutes, remove the sealant and reapply.

Clean the rear main bearing cap sealing area thoroughly and apply sealant to the rear main bearing cap to cylinder block grating 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.





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

Install the rear main bearing cap and start the bolts.





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





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





7. Tighten the bolts.
8. Lubricate the cylinder bores.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
9. Make sure that the piston rings are properly spaced.





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

Use Piston Ring Compressor to install the piston.
11. Lubricate the connecting rod bearings.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
12. Check the clearance of each connecting rod bearing.





13. Install the connecting rod cap and the nuts.





14. Position the oil pump and install the bolts.





15. Install the oil pump screen cover and tube.
1 Install the nut.
2 Position the gasket and install the bolts.





16. Lubricate the camshaft and install into the cylinder block.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





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

Install the camshaft thrust plate.
1 Lubricate and position the camshaft thrust plate. Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
2 Install the bolts.





18. Position the crankshaft sprocket, camshaft sprocket and the timing chain/belt while aligning the timing marks.





19. Install the bolt.
20. Lubricate the timing chain/belt and sprockets
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





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





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

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





23. Install the oil pan gasket.





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

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





25. Position the oil pan and reinforcement rails and install the 22 bolts.
1 Tighten the four end bolts.
2 Tighten the remaining 18 bolts.





26. Lubricate the crankshaft rear oil seal and crankshaft sealing surface.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





27. 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-19A53~RA or equivalent meeting Ford specification WSE-M5B392-A.

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





28. Check that the crankshaft rear oil seal is within specification.





29. Install a new water pump housing gasket and the water pump.





30. Position the water pump pulley and install the bolts.





31. CAUTION: Be sure to position the O-ring into the groove on the adapter. 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 bolt installation.

Install the bolt and O-ring.





32. Tighten the bolt.





33. Lubricate the engine front cover and front oil seal inner seal inner lip.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





34. Use Crankshaft Seal Replacer/Aligner to install the crankshaft front seal into the engine front cover.





35. 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.





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

Position the crankshaft pulley and install the bolt.





37. Position the Crankshaft Position Sensor (CKP sensor) and timing pointer and install the bolts.





38. NOTE: The RH is shown; the LH is similar.

NOTE: A specially treated composition gasket is used. Do not apply sealer to a composition gasket.

Position the head gasket over the two dowel pins.





39. Install the cylinder head on the head gasket and install the ten new bolts in three steps.
^ Step 1: Tighten to 34-47 Nm (25-35 ft. lbs.).
^ Step 2: Tighten to 61-75 Nm (45-55 ft. lbs.).
^ Step 3: Rotate an additional 85-90°.
40. Lubricate the valve tappet bores before installing the valve tappets.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





41. Install the valve tappets and the valve tappet guide plates in their original positions.





42. Position the valve tappet guide plate retainer and install the bolts.





43. Install the push rods in their original positions.
44. Apply engine oil to the top of the valve stems and rocker arm seats.
^ Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





45. Install the rocker arms and rocker arm fulcrum guides.





46. Install the eight rocker arm fulcrums.





47. Install the bolts.
48. Check the valve clearance.





49. NOTE: Use Metal Surface Cleaner F4AZ- l9A53~RA or equivalent meeting Ford specification WSE-M5B392-A to clean the gasket surfaces of the lower intake manifold, cylinder heads and cylinder block.

NOTE: The lower intake manifold must be installed within four minutes after applying the silicone.

Apply sealer in the comers where the cylinder head and cylinder block meet.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.





50. Position the four lower intake manifold gaskets.
^ Install intake manifold seal tabs to notch in the lower intake manifold gaskets.
^ Press firmly along the entire length of the intake manifold seal until the silicone sealant is visible.





51. Tighten the twelve bolts in two steps.
^ Step 1: 6-14 Nm(5-10 ft. lbs.).
^ Step 2: 31-34 Nm (23-25 ft. lbs.).
52. Install the Camshaft Position Sensor (CMP sensor) and camshaft synchronizer.





53. Connect the eight fuel injector electrical connectors.





54. Install the water bypass tube.
1 Position the water bypass tube.
2 Install the clamps.





55. Position the RH valve cover and install the bolts.





56. Position the LH valve cover and install the bolts.





57. Position the water heater tube fitting on the intake manifold and install the nut.





58. Install the nut.





59. Position the engine sensor control wiring and connect the oil pressure sensor electrical connector.





60. Connect the crankshaft position sensor electrical connector.





61. Connect the engine coolant temperature electrical connector.
62. Clean and inspect all surfaces. Install new seals and intake manifold gaskets.





63. Position the upper intake manifold and install the bolts.





64. Install the upper intake manifold cover plate.





65. Connect the two upper and the two PCV heater hoses.





66. Connect the following connections:
^ The Engine Vacuum Regulator (EVR) electrical connector.
^ The Engine Vacuum Regulator (EVR) vacuum connector.





67. Position the EGR valve to exhaust manifold tube and connect the lower fitting.





68. Connect the upper EGR valve-to-exhaust manifold tube fitting.





69. Connect the two pressure transducer hoses.





70. Connect the EGR valve vacuum connector.





71. Connect the TP sensor electrical connector.





72. Connect the Idle Air Control (IAC) bypass electrical connector.





73. Connect the crankcase ventilation hose to the throttle body.





74. Install the accelerator control splash shield and bolt.





75. CAUTION: These bolts require special torque values. Proper tightening is necessary to prevent excessive accessory drive vibrations.

Position the generator bracket and install the bolts (RH only).





76. NOTE: Make sure to tighten the generator bracket in two steps.

Tighten the bolts in the sequence shown (RH only).
^ Step No. 1-Tighten bolts 1 and 2 to 35 Nm (26 ft. lbs.).
^ Step No. 2-Tighten bolts 3 to 65 Nm (48 ft. lbs.).





77. Tighten the last bolt (RH only).





78. Position the drive belt tensioner and install the bolts.