Removal and Installation

REMOVAL
1. Remove engine from vehicle and place on a work stand. Remove accessory drive belt.
2. Remove oil pan and discard oil pan gasket.
3. Remove engine front cover.
4. Check timing chain deflection. Remove timing chain and crankshaft and camshaft sprocket.

CAUTION: If connecting rod bearings, crankshaft main bearings and crankshaft thrust main bearings are to be reused, they should be identified to make sure that they are installed in their original positions.

5. Invert engine on the work stand. Remove push rod. Remove oil pump screen cover and tube and oil pump.

NOTE: Make sure all bearing caps (main and connecting rod) are marked so that they can be installed in their original positions.

6. Turn crankshaft until the connecting rod, being serviced is in the up position. Remove connecting rod cap.

CAUTION: Install a 50 mm (2 inch) piece of 3/8-inch fuel line (or straight ignition wire spark plug boot) on both connecting rod bolts prior to installation to prevent damage to crankshaft rod journals.

7. Push connecting rod and piston assembly into the cylinder. Use caution not to let connecting rod damage the crankshaft journals. Repeat procedure for the remaining connecting rods.
8. Remove crankshaft main bearing caps.

CAUTION: Handle the crankshaft with care to avoid possible fracture or damage to the finished surfaces or possible engine damage may occur.

9. Carefully lift the crankshaft out of the cylinder block so that the upper main thrust bearing surfaces are not damaged.

INSPECTION
1. Remove crankshaft main bearings from cylinder block and main bearing caps.
2. Remove connecting rod bearings from the connecting rods and caps.
3. Inspect all machined surfaces on the crankshaft for nicks, scratches, scores, etc., which could cause premature bearing wear. Lightly stone all such surfaces.
4. Clean and inspect all components.
5. Inspect crankshaft journals. Testing and Inspection

INSTALLATION

CAUTION:
Make sure crankshaft main bearings and bearing bores are clean. Foreign material under the crankshaft main bearings will distort the crankshaft main bearing and cause a failure.

NOTE:
Main Bearing Caps: Installing
Crankshaft main bearing caps are precision fit to surrounding metal parts. A slight tap with a plastic mallet will help to locate cap. Use care to prevent damage.

Main Bearing Caps: Identifying
Main bearing caps are numbered with arrow heads. No.1 is located at front of engine with arrow head facing front of engine. No.2 is main bearing cap and has two arrow heads pointing to front of engine and so on.

Thrust Bearing
The third bearing from front is the crankshaft thrust main bearing.

1. If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize crankshaft main bearings.
2. Place upper crankshaft main bearings in position in the bores with the tang fitted in the slot provided.
3. Install lower crankshaft main bearings in main bearing caps.
4. Carefully lower crankshaft into place.
5. Check the clearance of each crankshaft main bearing. Select fit the crankshaft main bearings for proper clearance. Fitting/Oil Clearance Check

NOTE: Make sure main crankshaft bearing caps are installed in their original position and orientation.

6. After crankshaft main bearings have been fitted, apply a light coat of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to the journals, bearings and crankshaft rear oil seal surface.

NOTE: Take care to keep silicone sealer from parting surfaces between cylinder block and cap.

7. Install bearing caps No. 1 and 2 and tighten cap bolts to 45 Nm (20 ft. lbs.).

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealers ability to adhere.

8. Apply a 6 mm (1/4 inch) dot of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 to gap between rear crankshaft main bearing and cylinder block. Refer to Figure.
9. Install rear crankshaft main bearing cap and tighten to 45 Nm (20 ft. lbs.).
10. Align the Thrust main bearing Faces
A. Install the thrust bearing cap with the bolts finger-tight.
B. Pry the crankshaft forward against the thrust surface of the upper half of the crankshaft thrust main bearing.

NOTE: This will align the thrust surfaces of both halves of the crankshaft thrust main bearing

C. Hold the crankshaft cap to the rear. Retain the forward pressure on the crankshaft and tighten cap bolts to 45 Nm (20 ft. lbs.).
11. Check crankshaft end play: End Play
If end play exceeds specification, replace upper and lower crankshaft thrust main bearings. Install crankshaft thrust main bearings and align the faces. Recheck end play.
If the end play is less than specification, inspect thrust bearing faces for damage, dirt or improper alignment. Install crankshaft thrust main bearings and align the faces. Recheck end play.
12. Tighten all main bearing caps to 75-85 Nm (55-63 ft. lbs.). Check that crankshaft turns freely.
13. Install new connecting rod bearings and check the clearance of each connecting rod bearing. Refer to proper procedures.
14. If connecting rod bearing clearances are to specification, apply a light coat of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to the journals and connecting rod bearings.
15. Turn the crankshaft throw to the bottom of the stroke. Push the piston all the way down until the connecting rod bearing seats on the crankshaft journal.
16. Install lower connecting rod bearing and connecting rod cap. Tighten nuts. Tighten nuts evenly to 31-39 Nm (23-28 ft. lbs.).
17. After connecting rod bearings have been installed, check connecting rod crankshaft journal side clearance.
18. Turn engine on the work stand so that the front end is up. Install timing chain, crankshaft sprocket and camshaft sprocket, engine front cover, new crankshaft front seal and crankshaft pulley and damper.
19. Turn engine on the work stand so that the rear end is up and install crankshaft rear oil seal.
20. Clean oil pan, oil pump and oil pump screen cover and tube.
21. Prime oil pump by filling the inlet opening with oil and rotating the oil pump intermediate shaft until oil emerges from the outlet opening.
22. Install oil pump, oil pump screen cover and tube and oil pan.
23. Position flywheel on the crankshaft. Tighten to 73-87 Nm (54-64 ft. lbs.).
24. Turn engine on the work stand so that the engine is in the normal upright position. Install drive belt tensioner and accessory drive belt.
25. Remove engine from the work stand. Install engine.