Steps 1-70

Assembly

1. WARNING: EYE PROTECTION IS REQUIRED TO BE WORN DURING USE OF COMPRESSED AIR. FAILURE TO WEAR EYE PROTECTION COULD RESULT IN POSSIBLE PERSONAL INJURY.

NOTE: Prior to service reinstallation or replacement of fasteners, all threads and contact surfaces of fasteners must be lubricated with Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification ESE-M2C153-E unless specified.

Clean gasket material, dirt and debris from cylinder block. Wash cylinder block with a suitable soap and water solution. Dry cylinder block completely using compressed air.

2. If removed, install pipe plugs and alignment dowels to cylinder block. Apply Pipe Sealant with Teflon� D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to pipe plugs prior to installation. Tighten pipe plugs as follows:

- 3/8 Inch Pipe Plug-16-24 N.m (12-18 lb-ft).

- 1/2 Inch Pipe Plug-35-45 N.m (26-33 lb-ft).

- 3/4 Inch Pipe Plug-60-75 N.m (44-55 lb-ft).

- 1 Inch Pipe Plug -80-100 N.m (59-74 lb-ft).

3. If removed, install oil filter mounting insert. Tighten to 27-40 N.m (20-29 lb-ft).

4. With front of crankshaft supported by wood blocks, install crankshaft key into crankshaft keyway.







5. NOTE: Using a hammer, lightly tap crankshaft key into crankshaft keyway.

Using the 11-character code located on the cylinder block and crankshaft, select the proper grade of crankshaft main bearings as follows:

Read the 11-character code on the cylinder block face and the crankshaft flange.

A. The first two numbers after the first asterisk are the code for the No.1 main journal.

B. The second two numbers after the first asterisk are the code for the No.2 main journal.

C. The first two numbers after the second asterisk are the code for the No.3 main journal.

D. The last two numbers are the code for the No.4 main journal.







Using the Select Fit Main Bearing Grade Chart and the character codes noted above, move across and down the appropriate row and column to select the bearing grade for the No. 1 main journal.

Repeat the procedure for the other main journals.

6. Install upper crankshaft main bearings and upper crankshaft thrust washer into cylinder block. Insert crankshaft main bearing tang into slot in cylinder block.

7. CAUTION: When installing crankshaft, use care not to damage any crankshaft journal bearing surfaces.

Install crankshaft into cylinder block.

8. Lubricate upper crankshaft main bearings and crankshaft thrust washer with Engine Assembly Lubricant D9AZ-19579-D meeting Ford specification ESR-M99C80-A.

9. Install lower crankshaft main bearings and crankshaft thrust main bearing onto lower cylinder block.

10. Lubricate lower crankshaft main bearings and crankshaft thrust main bearing with Engine Assembly Lubricant D9AZ-19579-D meeting Ford specification ESR-M99C80-A.

11. Clean lower cylinder block to upper cylinder block sealing surfaces with a shop towel and Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.












12. Apply a 2-3 mm (0.070-0.118 inch) bead of Black Silicone Rubber F4AZ- 19562-B or equivalent meeting Ford specification WSK-M4G323-A1 to lower cylinder block sealing surface of cylinder block as illustrated.

13. Install lower cylinder block over cylinder block alignment dowels and onto upper cylinder block.












14. CAUTION: Lower cylinder block retaining bolt numbers 1 through 16 must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.

NOTE: Tighten all lower cylinder block to upper cylinder block retaining bolts within six minutes of installing lower cylinder block onto upper cylinder block.

NOTE: Do not lubricate lower cylinder block to upper cylinder block retaining bolts.

Install new torque-to-yield lower cylinder block to upper cylinder block retaining bolts number 1 through 16. Install removed non-yield lower cylinder block to upper cylinder block retaining bolts. Tighten lower cylinder block to upper cylinder block bolts in sequence shown at this time to 3-5 N.m (26-44 lb-in).

15. Push crankshaft rearward and then lightly, using a prybar or a similar tool, seat crankshaft thrust washer forward.







16. Tighten lower cylinder block to upper cylinder block retaining bolts in sequence, as follows:

- Tighten fasteners 1 through 8 to 22-28 N.m (16-21 lb-ft).

- Tighten fasteners 9 through 16 to 37-43 N.m (27-32 lb-ft).

- Rotate fasteners 1 through 16 an additional 85-95 degrees.

- Tighten fasteners 17 through 22 to 20-30 N.m (15-22 lb-ft).

17. Verify crankshaft rotates freely and does not bind. Clean any residual sealer from inside the cylinder block with a clean shop towel.







18. NOTE: Lubricate crankshaft flange and crankshaft rear oil seal bore inside diameter with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification (ESR-M99C80-A) prior to installation of crankshaft rear oil seal.

Install crankshaft rear oil seal using a Rear Main Seal Replacer T82L-670 1-A and Rear Crank Seal Replacer Adapter T91P-6701-A. Install crankshaft rear oil seal 2.0-0.0 mm (0.079-0.0 inch) flush to rear of cylinder block.







19. Check crankshaft end play in both directions as shown using Dial Indicator with Bracketry TOOL-4201-C or equivalent.

20. If disassembled, assemble pistons onto connecting rods as outlined. Service and Repair

21. If being replaced, assemble new piston rings onto pistons as outlined. Service and Repair

22. NOTE: The connecting rod bearing tangs should align with notch in connecting rod and cap.

Install connecting rod bearings into connecting rods and connecting rod caps.







23. CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Push piston down until connecting rod bearing seats on crankshaft journal.

NOTE: Lubricate pistons, piston rings, connecting rods and connecting rod bearings with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A prior to installation.

NOTE: Install with arrow on piston to front of engine.

Turn crankshaft until crankshaft throw is at bottom of stroke. Install correctly numbered piston and connecting rod with Piston Ring Compressor D81L-6002-C and Connecting Rod Guide Tool T94P-6136-AH.

24. CAUTION: It is imperative that the connecting rod cap be properly aligned to the connecting rod. The connecting rod and connecting rod cap bearing tangs must be located on same side of connecting rod.

CAUTION: Connecting rod bolts must be replaced with new bolts. They are torque-to-yield design and cannot be reused.

Install connecting rod cap and connecting rod bearing onto connecting rod. Alternately tighten new torque-to-yield connecting rod bolts in several passes to 35-45 N.m (26-33 lb-ft). Rotate connecting rod bolts 90-120 degrees.

25. After installation of each piston and connecting rod, rotate crankshaft to ensure smooth operation.







26. Check connecting rod side clearance using Dial Indicator with Bracketry TOOL-4201-C or equivalent. Side clearance should be 0.10-0.25 mm (0.004-0.010 inch).

If connecting rod side clearance is greater than maximum service limit, replace connecting rod and/or crankshaft.

27. Rotate inner rotor of oil pump to align with flat on crankshaft.

28. Carefully install oil pump onto crankshaft until seated against cylinder block.







29. Install oil pump retaining bolts and tighten in sequence to 8-12 N.m (71-106 lb-in).







30. Install oil pan battle and retaining nuts. Tighten nuts to 20-30 N.m (15-22 lb-ft).

31. Install oil pump screen cover and tube with a new 0-ring to oil pump. Tighten oil pump screen cover and tube retaining bolts to 8-12 N.m (71-106 lb-in).












32. Install new self-locking oil pump screen cover and tube support nut to lower cylinder block retaining stud bolt. Tighten nut to 20-30 N.m (15-22 lb-ft).

33. Turn engine right side up on engine stand.







34. If removed install engine coolant inlet tube into cylinder block with a Water Inlet Tube Replacer T94P-6312-BH and Drive Handle D8lP-4000-A or equivalent. Apply 2mm (0.070 inch) wide bead of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 to engine coolant inlet tube prior to assembly.

35. Install power steering bracket onto cylinder block. Install and tighten power steering bracket retainer bolts to 40-55 N.m (29-40 lb-ft).







36. Install new oil separator to cylinder block gasket, oil separator and retainer bolts to cylinder block. Tighten bolts 8-12 N.m (71-106 lb-in).

37. If disassembled, assemble cylinder heads as outlined. Service and Repair

38. NOTE: Clean cylinder head gasket surface with a toluene-based paint thinner or gasket remover. If gasket material remains on cylinder head after cleaning, use a plastic-tipped scraper and Scotch Brite or 600 grit sandpaper to remove remaining material.

NOTE: LH and RH head gaskets are not interchangeable.

Install new head gaskets on cylinder block. Head gaskets must be installed over cylinder head to block dowels.












39. CAUTION: Use care when positioning cylinder heads. Damage to cylinder block or cylinder heads may result.

NOTE: Ensure cylinder heads are installed in their original positions.

Install cylinder heads onto cylinder block over cylinder head to block dowels.







40. CAUTION: Cylinder head retaining bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused or damage to engine may occur.

Install new torque-to-yield cylinder head retaining bolts and tighten in sequence, as follows:

- Tighten bolts to 37-43 N.m (27-32 lb-ft).

- Rotate bolts 85-95 degrees.

- Loosen bolts a minimum of one full turn.

- Tighten bolts to 37-43N.m (27-32 lb-ft).

- Rotate bolts 85-95 degrees.

- Rotate bolts an additional 85-95 degrees.

41. Rotate crankshaft to position the keyway in the 11 o'clock location to position the crankshaft at top dead center (TDC) No.1 cylinder.

42. NOTE: Ensure valve tappets are installed in their original locations.

Lubricate valve tappets with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install valve tappets to cylinder heads.

43. CAUTION: Crankshaft must be at top dead center (TDC) No.1 cylinder prior to camshaft installation. Failure to do so may lead to engine damage.

Lubricate camshafts with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install camshafts into cylinder heads with timing arrows on sprocket pointing toward each other.












44. NOTE: Cylinder head camshaft journal thrust caps must be installed last to ensure that damage to the thrust caps does not occur.

NOTE: Ensure cylinder head camshaft journal caps are installed in original positions.

Loosely install cylinder head camshaft journal caps and retaining bolts.


45. Install LH timing chain crankshaft sprocket onto crankshaft. Align crankshaft key with keyway on crankshaft sprocket.

46. Install LH timing chain guide and retaining bolts to engine. Tighten LH timing chain guide retaining bolts to 20-30 N.m (15-22 lb-ft).

47. Install LH timing chain over LH crankshaft sprocket and LH camshaft sprockets. Align timing index marks on LH timing chain with timing index marks on LH crankshaft and camshaft sprockets.

48. Install LH timing chain tensioner arm over alignment dowel on LH cylinder head.












49. NOTE: Timing chain tensioners must be reinstalled onto engine while compressed and locked. Failure to compress timing chain tensioners prior to installation may cause damage to engine.

Install compressed LH timing chain tensioner and retaining bolts onto cylinder block. Tighten LH timing chain tensioner retaining bolts to 20-30 N.m (15-22 lb-ft).







50. Verify timing index marks on LH timing chain are in alignment with timing index marks on LH crankshaft sprocket and camshaft sprockets.

51. Install RH timing chain crankshaft sprocket onto crankshaft. Align crankshaft key with keyway on crankshaft sprocket.

52. Install RH timing chain guide and retaining bolts to engine. Tighten RH timing chain guide retaining bolts to 20-30 N.m (15-22 lb-ft).

53. Install RH timing chain over RH crankshaft sprocket and RH camshaft sprockets. Align timing index marks on RH timing chain with timing index marks on RH crankshaft sprocket and camshaft sprockets.

54. NOTE: Timing chain tensioners must be reinstalled onto engine while compressed and locked. Failure to compress timing chain tensioners prior to installation may cause damage to engine.

Install compressed RH timing chain tensioner arm over alignment dowel on RH cylinder head.












55. Install RH timing chain tensioner and retaining bolts onto cylinder block. Tighten RH timing chain tensioner retaining bolts to 20-30 N.m (15-22 lb-ft).

56. Verify timing index marks on RH timing chain are in alignment with timing index marks on RH crankshaft sprocket and camshaft sprockets.

57. CAUTION: Crankshaft keyway must be at the 11 o'clock location prior to installation of the LH cylinder head rocker arms. Failure to do so may lead to engine damage.

NOTE: Ensure rocker arms are installed in their original locations.

Lubricate rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install rocker arms onto LH cylinder head under camshafts while lifting camshafts.







58. CAUTION: Do not install LH cylinder head camshaft journal thrust caps until camshaft journal caps are installed or damage to the thrust caps may occur.

With LH cylinder head rocker arms installed, tighten LH cylinder head camshaft journal cap bolts in sequence shown to 8-12 N.m (71-106 lb-in).

59. With LH cylinder head camshaft journal caps installed and camshaft aligned with the thrust caps, install thrust caps and tighten retaining bolts to 8-12 N.m (71-106 lb-in).

60. Rotate crankshaft two revolutions and position the crankshaft keyway to the 3 o'clock location. This will position the RH cylinder head camshafts to the neutral position (base circle).

61. CAUTION: Crankshaft keyway must be at the 3 o'clock location. This will position the camshafts in neutral position prior to installation of the RH cylinder head rocker arms. Failure to do so may lead to engine damage.

NOTE: Ensure rocker arms are installed in their original locations.

Lubricate rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install rocker arms onto cylinder head under camshafts while lifting camshafts.

62. CAUTION: Do not install cylinder head camshaft journal thrust caps until camshaft journal caps are installed or damage to the thrust caps may occur.

With RH cylinder head rocker arms installed, tighten RH cylinder head camshaft journal cap bolts in sequence shown to 8-12 N.m (71 - 106 lb-in).

63. With RH cylinder head camshaft journal caps installed and camshaft aligned with the thrust caps, install thrust caps and tighten retaining bolts to 8-12 N.m (71-106 lb-in).

64. Remove lock pins from LH and RH timing chain tensioners.







65. Verify timing index marks on timing chains are in alignment with timing index marks on crankshaft sprockets and camshaft sprockets.

66. Install crankshaft position (CKP) sensor pulse ring onto crankshaft. Align crankshaft key with keyway on CKP sensor pulse ring.

67. Clean engine front cover to cylinder block and cylinder head sealing surfaces using a clean shop towel and Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.












68. NOTE: Install engine front cover and retaining bolts and stud bolts in the locations and sequence shown in no more than six minutes after applying sealer.

Apply a 3 mm (0.118 inch) diameter bead, approximately 12mm (0.472 inch) long, of Black Silicone Rubber F4AZ-19562-B or equivalent sealant meeting Ford specification WSE-M4G323-A1 in six locations on cylinder block as shown.

69. Install engine front cover with new engine front cover gaskets over alignment dowels to cylinder block and cylinder heads.

70. Install engine front cover retaining bolts and stud bolts in locations and sequence as shown a 1/4 turn in no more than six minutes after applying sealer.