Steps 1 - 44
ASSEMBLYEngine
Special Tools And Equipment, Part 1:
Special Tools And Equipment, Part 2:
Special Tools And Equipment, Part 3:
Special Tools
Material, Part 1:
Material, Part 2:
Material
Engine - Upper End
Engine Induction System
Engine - Lower End
Engine Front End
NOTE: During engine assembly it may become necessary to check bearing clearances, end play, etc.
1. Read the first character code information on the cylinder block face (1) and record the information.
2. Read the first character on the No. 7 crankshaft counterweight and note it.
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 block 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 number one 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 a "2."
^ Repeat this process for the remaining 4 mm bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings chart to determine the required bearing 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 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 and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
9. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.
10. NOTE: Make sure to tighten the bolts in 4 stages.
Tighten the bolts in 4 stages.
^ Stage 1: Tighten bolts 1 through 20 in sequence to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten bolts 1 through 10 in sequence to 25 Nm (18 ft. lbs.).
^ Stage 3: Tighten bolts 11 through 20 in sequence to 40 Nm (30 ft. lbs.).
^ Stage 4: Tighten bolts 1 through 20 in sequence an additional 90 degrees.
11. Install and tighten the cross mounted bolts in 2 stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
12. Check the piston to cylinder block and piston ring clearances.
13. Install the piston rings.
14. Make sure the ring gaps (oil spacer A, oil ring B, compression ring C) are correctly spaced around the circumference of the piston.
15. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: The following piston installation steps are for all 8 connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.
Use the special tools to install the connecting rod with upper connecting rod bearing in place.
^ Lubricate the piston and ring with clean engine oil.
^ Lubricate the rod bearings with clean engine oil.
16. CAUTION: 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 special tool.
17. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.
NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
Position the lower bearing and connecting rod cap and install the new bolts loosely.
18. NOTE: Main caps are not shown for clarity.
Tighten the bolts in 3 stages, using the sequence shown.
^ Stage 1: Tighten to 23 Nm (17 ft. lbs.).
^ Stage 2: Tighten to 43 Nm (32 ft. lbs.).
^ Stage 3: Tighten an additional 90 120 decrees.
19. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown to 10 Nm (89 inch lbs.).
20. CAUTION: Make sure all coolant residue and foreign material is cleaned from the block surface and the cylinder bore.
CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean.
CAUTION: The use of the sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: The new gasket has a film coating which is crucial to the gaskets ability to seal correctly. Do not scratch the gasket.
NOTE: RH shown, LH similar.
Install the head gaskets over the dowel pins.
21. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.
CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation.
Tighten the LH cylinder head bolts in 6 stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).
^ Stage 3: Back out 1 full turn (360 degrees).
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees (1/4 turn).
^ Stage 6: Tighten an additional 90 degrees (1/4 turn).
22. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.
CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation.
Tighten the RH cylinder head bolts in 6 stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).
^ Stage 3: Back out 1 full turn (360 degrees).
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees (1/4 turn).
^ Stage 6: Tighten an additional 90 degrees (1/4 turn).
23. NOTE: Lubricate O-ring seal with clean engine oil.
Install the oil level indicator tube.
^ Install a new O-ring seal on the oil level indicator tube.
^ Install the oil level indicator tube.
^ Install the bolt and tighten it to 10 Nm (89 inch lbs.).
24. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown to 20 Nm (15 ft. lbs.).
25. Install the RH exhaust manifold heat shield and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
26. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown to 20 Nm (15 ft. lbs.).
27. Install the LH exhaust manifold heat shield and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
28. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Prior to installation, inspect the tensioner sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
NOTE: The following 2 steps must be performed on both hydraulic chain tensioners.
Compress the tensioner plunger, using a vise.
29. Install a retaining clip on the tensioner to hold the plunger in during installation.
30. If the copper links are not visible, mark one link on one end and one link on the other end and use as timing marks.
31. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and/or valve damage will occur.
Using the special tool, position the crankshaft.
32. Install the crankshaft sprocket with the flange facing forward.
33. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install and tighten the bolts to 10 Nm (89 inch lbs.).
3 Position the RH timing chain guide.
4 Install and tighten the bolts to 10 Nm (89 inch lbs.).
34. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
35. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
36. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the LH timing chain on the camshaft sprocket. Make sure the copper colored link aligns with the camshaft sprocket timing mark.
37. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
38. Remove the retaining clip from the LH timing chain tensioner.
39. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
40. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the RH timing chain on the camshaft sprocket. Make sure the copper colored link aligns with the camshaft sprocket timing mark.
41. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
42. Remove the retaining clip from the RH timing chain tensioner.
43. As a post check, verify correct alignment of all timing marks.
44. Install the crankshaft sensor ring on the crankshaft.