Assembly

CAUTION: Do not use abrasive grinding discs to remove the gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.

NOTE:
- During assembly, all bearing surfaces must be lubricated before assembly or installation.
- The crankshaft main bearings are precision selective fit.





1. Install the (A) upper crankshaft main bearings and the (B) crankshaft thrust main bearing.





2. Install the crankshaft.





3. Install the five lower crankshaft main bearings and the five main bearing caps.

NOTE:
- The crankshaft main bearings are numbered 1 to 5 with No. 1 at the front of the engine. Make sure the arrow faces the front of the engine.
- Apply axial load to the rear of the crankshaft simultaneously to tightening of the bolts.





4. Install the piston and connecting rod assemblies.





5. Install the four connecting rod caps.





6. Use Crankshaft Real Seal Pilot and Crankshaft Rear Seal Replacer to replace the crankshaft rear oil seal.

NOTE:
- Coat the rear oil seal area and the crankshaft rear oil seal lip with Super Premium 5W30 SAE Motor Oil XO-SW30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
- Ensure the crankshaft rear oil seal is on correctly and that the edges are not rolled over.





7. Install a new crankshaft rear oil seal retainer gasket and install the crankshaft rear seal retainer.





8. Install the oil pump.





9. Install the oil baffle.





10. Install the oil pump screen and cover assembly.
11. Clean and inspect the mounting faces of both the oil pan and the cylinder block. To remove all traces of previous sealer, use solvent to clean the cylinder block and oil pump. Both surfaces must be flat, clean, and dry.
12. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 approximately 3.0 mm (0.125 in) wide at the oil pan to cylinder block joints and the crankshaft rear oil seal retainer to cylinder block joints.

NOTE: Install the oil pan within ten minutes after the sealer is applied.

13. Install the oil pan gasket in the oil pan.

NOTE: Ensure the press fit tabs are fully engaged in the oil pan gasket channel when installing the oil pan gasket and oil pan.





14. Install the oil pan. Tighten the bolts in the sequence shown.

NOTE: The rear edge of the oil pan must be aligned with the rear face of the cylinder block using a straight edge.





15. Install the cylinder head assembly and torque the cylinder head bolts in the following sequence.
- Tighten all the bolts in a single sequence to 40-60 Nm (30-44 ft. lbs).
- Back the bolts off 1/2 turn.
- Tighten the bolts in the sequence shown to 40-60 Nm (30-44 ft. lbs).
- Rotate all the bolts in a single sequence an additional 180 degrees in two steps of 90 degrees each.

CAUTION: Always use new cylinder head bolts.

NOTE: Lubricate the cylinder head bolts with engine oil prior to installation.





16. Install the valve cover gasket and valve cover.





17. Install the engine mounting bracket.





18. Install the front engine accessory drive bracket.





19. Install the power steering pump.





20. Use Strap Wrench and install the power steering pump pulley.





21. Install the timing belt guide and the crankshaft sprocket.





22. Install the inner engine front cover.





23. Install the water pump.





24. Install the camshaft sprocket.





25. Install the timing belt tensioner.





26. Install the (A) timing belt, remove the (B) 1/8 inch drill bit, and release the (C) timing belt tensioner.

NOTE: Install the timing belt over the sprockets in a counterclockwise direction starting at the crankshaft. Keep the belt span from the crankshaft to the camshaft tight while installing the timing belt over the camshaft.





27. Tighten the bolt.
28. Roll the engine over two times and recheck the timing marks.





29. Install the outer engine front cover.





30. Install the crankshaft position sensor.





31. Use Strap Wrench and install the crankshaft pulley.





32. Install the crankcase vent oil separator.
33. Install the spark plugs.





34. Install a new gasket and the water outlet connection.





35. Install the ignition coil mounting bracket assembly.





36. Install the radio ignition interference capacitor and the ignition coil.





37. Install a new gasket and the exhaust manifold.

NOTE: Tighten the bolts evenly and sequentially.





38. Install the generator.





39. Install the oil pressure switch.
40. Install the knock sensor.





41. Install the oil filter.
42. Install the spark plug wires.





43. Install the intake manifold runner control (IMRC) and the intake manifold.
44. Install the fuel charging wiring harness.





45. Connect the following electrical connectors:
- Water temperature indicator sender unit.
- Temperature gauge.
- Radio interference capacitor.
- Ignition coil.
- Intake manifold runner control.
- Knock sensor.
- Fuel pressure sensor.





46. Connect the (A) idle air control valve and the (B) throttle position sensor electrical connectors.





47. Connect the four fuel injector electrical connectors.





48. Connect the crankshaft position sensor electrical connector.





49. Install the oil level indicator tube.





50. Connect the EGR tube to the exhaust manifold.





51. Install a new gasket and install the EGR tube to the EGR valve.