Steps 1 - 49

1. Make sure that all engine mating surfaces are free of old sealant material.
2. Thoroughly lubricate the crankshaft main bearings with Super Premium SAE 5W-30 XO-5W30-QSP meeting Ford specification WSS-M2C153-G.
3. Install the upper crankshaft main bearings into the cylinder block.





4. CAUTION: The crankshaft is heavy. Be careful not to damage it when placing it in the cylinder block.

Carefully place the crankshaft into the cylinder block.
5. Install the lower crankshaft main bearings into the crankshaft main bearing cap.
6. Measure the crankshaft main bearing oil clearance.





7. Position the crankshaft main bearing cap.





8. Place the crankshaft main bearing cap in the correct position by shifting the crankshaft in the axial position.





9. NOTE: Thoroughly lubricate the crankshaft main bearing cap bolts with Super Premium SAE 5W-30 XO-5W30-QSP meeting Ford specification WSS-M2C153-G.

Install crankshaft main bearing cap bolts in the sequence shown using a three stage method.
- Stage 1: 30 Nm (22 ft. lbs.)
- Stage 1: 60 Nm (44 ft. lbs.)
- Stage 1: 90 Nm (66 ft. lbs.)

10. Rotate the crankshaft to make sure it turns smoothly.
11. Measure crankshaft end play.
12. Rotate the crankshaft until the appropriate crankshaft journal is at Bottom Dead Center (BDC).





13. Install two pieces of rubber hose over the connecting rod bolts to prevent crankshaft journal contact.





14. NOTE: Make sure all six piston rods are installed into the original cylinder bores during assembly.

NOTE: All six pistons and rod assemblies are installed the same way. Only one piston and rod assembly is shown.

NOTE: The connecting rod assemblies are numbered designating to which connecting rod each cap belongs.

NOTE: Use a hammer handle or a piece of wood to tap the piston and connecting rod into the cylinder bore. Guide the connecting rod bolts over the crankshaft journal.

NOTE: Make sure during installation of the piston assemblies that the front mark on the piston head faces toward the front of the engine.

NOTE: Dip the pistons into Super Premium SAE 5W-30 XO-5W30-QSP meeting Ford specification WSS-M2C153-G.

Install the pistons.
15. Remove the rubber hoses from the connecting rod bolts.





16. CAUTION: Install the bearings so the oil hole in the connecting rod aligns with the oil hole in the connecting rod bearing or bearing damage will occur.

NOTE: Coat the connecting rod bearings with Super Premium SAE 5W-30 XO-5W30-QSP meeting Ford specification WSS-M2C153-G.

Install the connecting rod bearings into the connecting rods and install the connecting rod caps.
17. Check connecting rod bearing oil clearance.





18. Tighten the connecting rod nuts in two stages.
- Stage 1: 15 Nm (11 ft. lbs.)
- Stage 2: 40 Nm (30 ft. lbs.)

19. Measure connecting rod side clearance.
20. Install a new crankshaft rear oil seal on the crankshaft rear oil seal retainer plate.





21. Install the crankshaft rear oil seal retainer plate.
1. Position the crankshaft rear oil seal retainer plate.
2. Install the bolts.





22. Install the oil pump.
1. Position the oil pump.
2. Install the short bolts.
3. Install the long bolt.





23. Install the generator bracket.
1. Position the generator bracket.
2. Install the bolt.





24. NOTE: Make sure the oil pan is free of old sealant material.

Install new oil pan seals on the oil pan.
- Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4 to the oil pan seals.





25. Apply a bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4 to the oil pan as shown.





26. Position the oil pan and install the oil pan bolts in the sequence shown.





27. Install the crankshaft sprocket
1. Install the crankshaft key.
2. Install the inner timing belt guide.
3. Install the crankshaft sprocket.

28. NOTE: Make sure the mating surface between the water pump and the cylinder block are free of old sealant material.

Install the water pump gasket to the water pump.





29. Position the water pump and install the bolts.





30. NOTE: Cylinder head installation is the same for both cylinder heads. Repeat the installation procedure for both cylinder heads.

Position the cylinder head gasket.





31. Position the cylinder head.





32. CAUTION: The cylinder head bolts located in positions 4, 7, 9, and 12 are 127 mm (5.08 inch) in length and all others are 106 mm (4.24 inch) in length.

CAUTION: The cylinder head bolt washers must be installed with the chamfered edge facing away from the cylinder head surface.

CAUTION: It is necessary to apply Super Premium SAE 5W-30 XO-5W-30-QSP or equivalent meeting Ford specifications WSS-M2C153-G to the threads and seating surfaces of the cylinder head bolts before installing.

Install the cylinder head bolts in the sequence shown.
1. Stage 1: Tighten the bolts to 29 Nm (21 ft. lbs.).
2. Stage 2: Tighten the bolts to 59 Nm (44 ft. lbs.).





33. Loosen the cylinder head bolts completely in the sequence shown.





34. Tighten the cylinder head bolts in the sequence shown.

NOTE: This torque sequence is not finished until the final 2 torque steps are applied after the intake manifold initial installation.





35. Install the knock sensor
1. Position the knock sensor.
2. Install the bolt.
3. Connect the electrical connector.





36. Install the coolant crossover tube.
1. Position the coolant crossover tube.
2. Install the bolts.





37. Install the lower intake manifold gaskets.





38. Position the lower intake manifold.





39. Install the lower intake manifold bolts and nuts in the sequence shown.
1. Stage 1: Tighten all bolts and nuts to 4 Nm (36 inch lbs.).
2. Stage 2: Tighten all bolts and nuts to 18 Nm (13 ft. lbs.).
3. Stage 3: Tighten all bolts and nuts to 18 Nm (13 ft. lbs.).





40. Loosen the lower intake manifold bolts and nuts completely in the sequence shown.





41. Tighten the cylinder head bolts in the sequence shown using a two stage method.
1. Stage 1: Tighten the bolts to 29 Nm (21 ft. lbs.).
2. Stage 2: Tighten the bolts to 59 Nm (44 ft. lbs.).





42. Install the last cylinder head bolt.





43. Tighten the lower intake manifold bolts and nuts in the sequence shown using a two stage method.
- Stage 1: Tighten all the bolts and nuts to 4 Nm (35 inch lbs.).
- Stage 2: Tighten all the bolts and nuts to 9 Nm (80 inch lbs.).
- Stage 3: Tighten all the bolts and nuts to 9 Nm (80 inch lbs.).

44. Inspect the valve tappets.





45. Install the rocker arm shaft support.
1. Position the rocker arm shaft support.
2. Remove the rubber bands.





46. CAUTION: Set the camshaft lobes so that the valves are not lifted. Tightening the rocker arm shaft bolts with the valves lifted can result in damaged valve components.

CAUTION: The rocker arm shaft bolts must be tightened using a two step method.

Install the rocker arm shafts and rocker arms.

1. Position the rocker arm shafts and rocker arms.
2. Install the 12 bolts using two steps to tighten.





47. NOTE: Valve cover gasket installation is the same for both sides. Use the installation procedure to install both valve cover gaskets. Make sure that all mating surfaces are free of old sealant material.

Install the valve cover gasket.





48. NOTE: Valve cover installation is the same for both sides. Use the installation procedure to install both valve covers. Make sure that all mating surfaces are free of old sealant material.

Install the valve cover.
1. Position the valve cover.
2. Install the screws.
49. Install new exhaust manifold gaskets on the cylinder heads.