Assembly
CAUTION:
Component Locations
The location of each precision machined component should be noted. When engine is assembled each component should be installed in its original position. These components include:
- Rocker arms, push rods, rocker arm seats and valve tappets.
- Crankshaft main bearings and bearing caps.
- Connecting rod bearings and bearing caps.
- Pistons, piston rings and piston pins.
Rust Prevention
If the components are not inspected or assembled within 2-4 hours, of cleaning, coat with engine oil to prevent rust.
Corrosion Damage/Cooling System Requirements
This engine has aluminum components and requires a special corrosion inhibiting coolant to avoid cooling system damage. Refer to Cooling System for proper specifications and procedures.
Cleaning Aluminum Surfaces
Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.
NOTE:
Gasket Maker Usage
During the engine assembly, a Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5 will be applied to many areas before installation. When the sealant is applied, the component should be installed within 15 minutes. After this time the sealant begins to set-up and its sealing effectiveness can be reduced.
Lubricating Fasteners
Lightly oil all retaining bolt and stud bolt threads before installation except those specifying special sealant.
PROCEDURES
NOTE: Before installation, coat plug threads with Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-AZ and ESR-M18P7-A.
1. If removed, install oil gallery and cooling jacket plugs. Tighten plugs to 20 Nm (14 ft. lbs.).
2. Install crankshaft, follow proper procedure.
3. Install crankshaft rear oil seal.
NOTE: Make sure piston ring lands are completely clean of carbon deposits before installing rings. Follow proper procedures for cleaning and inspecting pistons, piston rings and piston pins.
4. Check piston ring end gap in each cylinder.
5. Install piston rings on pistons using a ring expander.
6. Install the piston as follows:
Piston & Rod Assembly:
NOTE: Lightly oil all retaining bolt and stud bolt threads before installation except those specifying special sealant.
A. Lubricate cylinder wall and piston with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
CAUTION: Make sure piston ring end gaps are NOT aligned before installing.
B. Install a 50 mm (2 inch) piece of 3/8 inch fuel hose (or similar protector) on the connecting rod studs.
CAUTION: As piston is tapped into bore with a wooden hammer handle, guide connecting rod onto crankshaft journal to avoid damage to bearing surfaces.
NOTE:
Connecting rod and cap are not identified to cylinder position. The connecting rods and caps are identified with matching correlation letters. Letters on the connecting rod and cap must be on the same side when installed in the cylinder bore. If a connecting rod is transposed from one cylinder block or cylinder to another, new connecting rod bearings should be fitted.
Install the pistons in the same cylinders from which they were removed or to which they were fitted. Make sure notch in piston dome faces the front of engine and machine locating boss is facing RH side of engine.
C. Install piston using Rotunda Piston Ring Compressor 014-00290 or equivalent.
D. Lubricate bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
E. Make sure connecting rod is seated on crankshaft journal and install connecting rod cap. Tighten the cap retaining nuts to 31-39 Nm (23-28 ft. lbs.).
7. Check connecting rod bearing clearance and service as required. Service and Repair
8. Check camshaft oil clearance and service as required. Testing and Inspection
9. Install camshaft rear bearing cover. Refer to Camshaft Service and Repair.
10. Install camshaft and check camshaft end play. Follow proper procedure.
CAUTION: Check timing chain freeplay if it was not checked during disassembly.
Fig. 8 Timing Chain Alignment:
11. Install timing chain and camshaft sprocket and crankshaft sprocket as an assembly. Lubricate timing chain with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
12. Rotate crankshaft and camshaft to align sprocket timing marks as shown.
CAUTION: Check the drilled oil passages of the bolt to make sure they are not plugged. Clean as required. Do NOT replace with a standard bolt.
13. Install camshaft sprocket retaining bolt and washer and tighten to 50-70 Nm (37-51 ft. lbs.).
14. Install the water pump/engine front cover as an assembly and a new engine front cover gasket. Tighten water pump retaining bolts. Follow proper procedure.
15. Install oil pump/oil pump intermediate shaft assembly. If installing new oil pump, insert oil pump intermediate shaft into oil pump hex drive hole until oil pump intermediate shaft retaining ring clicks into place.
16. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
17. Install oil pan. Follow proper procedure.
18. Lubricate oil bypass filter gasket with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install oil bypass filter.
19. Lubricate valve tappets with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install into their original positions relative to camshaft lobe and push rod.
NOTE: Make sure the "UP" designation is facing the cylinder head.
20. Install new head gaskets onto cylinder block.
21. Install cylinder heads using new retaining bolts.
22. Install lower intake manifold.
23. Install pushrods and lifters. Follow pushrod replacement procedure.
24. Install thermostat and water hose connection and water hose connection gasket as illustrated, if removed. Tighten retaining bolts to 10-14 Nm (89-123 inch lbs.).
25. Install fuel injection supply manifold and fuel injectors if removed:
a. Apply Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to fuel injector bores in lower intake manifold and fuel injection supply manifold.
b. Install fuel injection supply manifold and fuel injectors.
c. Install fuel injection supply manifold retaining bolts and tighten to 8-12 Nm (71-106 inch lbs.).
26. Install valve covers. Follow proper procedure.
27. Install oil filler cap.
28. Install the engine control sensor wiring to the appropriate locations. Locate and install harness retainers to the valve cover retaining stud bolts.
29. Install upper intake manifold and new intake manifold upper gasket.
CAUTION: If a new camshaft and/or camshaft position sensor housing is installed, ALWAYS add the rest of the Engine Assembly Lubricant D9AZ-19579-D or equivalent (pint) meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the camshaft position sensor housing hole onto the camshaft drive gear. Run engine at idle for five minutes prior to driving vehicle.
30. Coat entire camshaft position sensor housing gear with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install camshaft position sensor (CMP sensor).
31. Install retaining bolt and washer. Tighten to 24 Nm (17 ft. lbs.).
32. Install exhaust manifolds. Tighten retaining bolts to 20-25 Nm (15-18 ft. lbs.).
33. Apply Perfect Seal Sealing Compound B5A-19554-A or F2AZ-19554-A or equivalent meeting Ford specifications ESR-M18P2-A and ESE-M4G115-A to bottom of oil level indicator tube.
34. Install oil level indicator tube and tighten retaining nut to 16-20 Nm (12-14 ft. lbs.).
35. Install spark plugs. Refer to Powertrain Management.
36. Connect ignition wires to spark plugs. Locate with ignition wire separators to appropriate valve cover retaining stud bolts.
NOTE: Apply Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to keyway slot in damper and lubricate outside of damper hub with clean engine oil meeting Ford specification WSS-M2C153-F prior to installation.
37. Install crankshaft damper using Vibration Damper and Seal Replacer T82L-6316-A. Tighten retaining bolt to 125-165 Nm (93-121 ft. lbs.).
38. Install oil pan. Tighten retaining bolts to 10-14 Nm (89-123 inch lbs.) in the standard cross-tightening sequence.