Steps 1-65

NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.

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

NOTE: Prior to service reinstallation or replacement of fasteners, all threads and contact surfaces of fasteners must be lubricated with Motorcraft Super Premium Motor Oil XO-5W30-QSP or DSP or equivalent meeting Ford specification WSE-M2C153-G 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 & circle; D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to pipe plugs prior to installation. Tighten pipe plugs in two steps as follows:
- 3/8-inch pipe plug-Step 1 Tighten to 20 Nm (15 ft. lbs.). Step 2 Tighten an additional 180 degrees.
- 1/2-inch pipe plug-Step 1 Tighten to 40 Nm (30 ft. lbs.). Step 2 Tighten an additional 180 degrees.
- 3/4-inch pipe plug-Step 1 Tighten 10 Nm (88 inch lbs.). Step 2 Tighten an additional 720 degrees.
3. If removed, install oil filter mounting insert. Tighten to 27-40 Nm (20-29 ft. lbs.).
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.
- The first two numbers after the first asterisk are the code for the No. 1 main journal.
- The second two numbers after the first asterisk are the code for the No. 2 main journal.
- The first two numbers after the second asterisk are the code for the No. 3 main journal.





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

Select Fit Crankshaft Main Bearing Grade Chart:

- 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. NOTE: Visually check seating and squareness of all bearings. Make sure all oiling holes align with cylinder block oil feed holes.

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 or equivalent 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 D9A2-1 9579-D or equivalent 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-1 9A536-RA or equivalent meeting Ford specification WSE-M513392-A to remove all residues that may interfere with the sealer's ability to adhere.

12. NOTE: Lower cylinder block must be installed and bolts tightened within four minutes of sealer application.





Apply a 1 mm (0.03937 inch) bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-IVI2G343-A4 to lower cylinder block sealing surface of cylinder block and a 3 mm (0.118 inch) bead at grooves as illustrated.

Crankshaft And Crankshaft Main Bearings (1 Of 2):

Crankshaft And Crankshaft Main Bearings (2 Of 2):

13. Install lower cylinder block over eight 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: Do not rotate crankshaft until all lower cylinder block retaining bolts are tightened to specification.

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

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

Cylinder Block Installation Sequence:

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.

Lower Cylinder Block Installation (1 Of 2):

Lower Cylinder Block Installation (2 Of 2):

15. Tighten lower cylinder block to upper cylinder block bolts in sequence shown at this time to 3-5 Nm (27-44 inch lbs.).
16. Push crankshaft rearward and then lightly, using a prybar or a similar tool, seat crankshaft thrust washer forward.

Cylinder Block Installation Sequence:

17. Tighten lower cylinder block to upper cylinder block retaining bolts in sequence, as follows:
- Tighten fasteners 1 through 8 to 22-28 Nm (17-20 ft. lbs.)
- Tighten fasteners 9 through 16 to 37-43 Nm (28-31 ft. lbs.)
- Rotate fasteners 1 through 16 an additional 85-95 degrees.
- Tighten fasteners 17 through 22 to 20-30 Nm (15-22 ft. lbs.)
18. Verify crankshaft rotates freely and does not bind. Clean any residual sealer from inside the cylinder block with a clean shop towel.

19. NOTE: Lubricate crankshaft flange and crankshaft rear oil seal 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 303-178 (T82L-8701-A) and Rear Crank Seal Replacer Adapter 303-384 (T9 1P-6701-A). Install crankshaft rear oil seal 2.0-0.0 mm (0.079-0.0 inch) flush to rear of cylinder block.

20. NOTE: Crankshaft end play must be within 0.110-0.232 mm.





Check crankshaft end play in both directions as shown using Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent.
21. If disassembled, assemble pistons onto connecting rods.

22. NOTE: If required, deglaze the cylinder walls using a suitable spring type tool. Clean the cylinder walls with a detergent and water solution with the engine upside down to prevent contamination of the crankshaft and bearings.

If being replaced, assemble new piston rings onto pistons.

23. 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.

24. 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 303-D032 (D81L-6002-C) or equivalent and Connecting Rod Guide Tool 303-462 (T94P-6136-AH).

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

CAUTION: Connecting rod bolts must be replaced with new bolts. They are torque-to-yield designed 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 40-45 Nm (30-33 ft. lbs.). Rotate connecting rod bolts 90-120 degrees.

26. After installation of each piston and connecting rod, rotate crankshaft to verify smooth operation.

27. NOTE: Position crankshaft so that piston, pin and rings are below the cylinder block surface to prevent damage to the piston, pin and ring.

Check connecting rod side clearance using Dial Indicator with Bracketry 100-002 (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.
28. Rotate inner rotor of oil pump to align with flat on crankshaft.
29. Carefully install oil pump onto crankshaft until seated against cylinder block.





30. Install oil pump retaining bolts and tighten in sequence to 8-12 Nm (71-106 inch lbs.)





31. Install oil pan baffle and retaining nuts. Tighten nuts to 20-30 Nm (15-22 ft. lbs.)
32. Install oil pump screen cover and tube with a new O-ring to oil pump. Tighten oil pump screen cover and tube retaining bolts to 8-12 Nm (71-106 inch lbs.)

Oil Pump Screen Cover And Tube (1 Of 2):

33. Install new self-locking oil pump screen cover and tube support nut to lower cylinder block retaining stud bolt. Tighten nut to 8-12 Nm (71-106 inch lbs.)
34. Turn engine right side up on engine stand.





35. If removed install engine coolant inlet tube into cylinder block with a Water Inlet Tube Replacer 303-467 (T94P-6312-BH) and Drive Handle 205-D055 (D81L-4000-A) or equivalent. Apply 2mm (0.070 inch) wide bead of Gasket Maker F8AZ-1913508-AB or equivalent meeting Ford specification WSK-M2G348-A5 to engine coolant inlet tube prior to assembly.





36. Install new oil separator to cylinder block gasket, oil separator and retainer bolts to cylinder block. Tighten bolts 8-12 Nm (71-106 inch lbs.).
37. If disassembled, assemble cylinder heads.

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 & circle; 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: Make sure 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.

Cylinder Head Installation Sequence:

Install new torque-to-yield cylinder head retaining bolts and tighten in sequence, as follows:
- Tighten bolts to 37-43 Nm (28-31 ft. lbs.).
- Rotate bolts 85-95 degrees.
- Loosen bolts a minimum of one full turn.
- Tighten bolts to 37-43 Nm (28-31 ft. lbs.).
- Rotate bolts 85-95 degrees.
- Rotate bolts an additional 85-95 degrees.





41. Install EGR backpressure transducer and mounting bracket to the rear of the RH cylinder head. Tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).
42. Rotate crankshaft to position the keyway in the 11 o'clock location to position the crankshaft at top dead center (TDC No. 1 cylinder.

43. NOTE: Make sure 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.

44. 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 flags (marked RFF) on rear of sprockets pointing toward each other.

Camshaft And Rocker Arm Installation LH Shown, RH Similar:

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

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

Loosely install cylinder head camshaft journal caps and retaining bolts.
46. Install LH timing chain crankshaft sprocket onto crankshaft. Align crankshaft key with keyway on crankshaft sprocket.
47. For engines equipped with 8 mm (0.32 in) timing chains, if the timing marks on the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.

1. Mark any link to use as the crankshaft timing mark.
2. Starting with the crankshaft timing mark, count 29 links and mark the link as the exhaust cam sprocket timing mark.
3. Continue counting to link 42. Mark the link as the intake sprocket timing mark.






48. Install LH timing chain guide and retaining bolts to engine. Tighten LH timing chain guide retaining bolts to 20-30 Nm (15-22 ft. lbs.).
49. Install LH timing chain over LH crankshaft sprocket and LH camshaft sprockets. Align timing index links on LH timing chain with timing index marks on LH crankshaft and camshaft sprockets.
50. Install LH timing chain tensioner arm over alignment dowel on LH cylinder head.

51. 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.

LH Timing Chain:

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

Timing Chain Index Marks:

52. Verify timing index links on LH timing chain are in alignment with timing index marks on LH crankshaft sprocket and camshaft sprockets.
53. Install RH timing chain crankshaft sprocket onto crankshaft. Align crankshaft key with keyway on crankshaft sprocket.
54. Install RH timing chain guide and retaining bolts to engine. Tighten RH timing chain guide retaining bolts to 20-30 Nm (15-22 ft. lbs.)
55. Install RH timing chain over RH crankshaft sprocket and RH camshaft sprockets. Align timing index links on RH timing chain with timing index marks on RH crankshaft sprocket and camshaft sprockets.

56. CAUTION: 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.

RH Timing Chain:

Install compressed RH timing chain tensioner arm over alignment dowel on RH cylinder head.
57. Install RH timing chain tensioner and retaining bolts onto cylinder block. Tighten RH timing chain tensioner retaining bolts to 20-30 Nm, (15-22 ft. lbs.)
58. Verify timing flags (marked RFF) on camshaft sprockets are pointing toward each other. Verify timing index links on RH timing chain are in alignment with timing index marks on RH crankshaft sprocket and camshaft sprockets.

59. 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 camshaft damage.

NOTE: Make sure rocker arms are installed in their original locations.

Lubricate rocker arms by immersing rocker arm in Engine Assembly Lubricant D9AZ-1 9579-D or equivalent meeting Ford specification ESR-M99C80-A and install rocker arms onto LH cylinder head under camshafts while lifting camshafts.

60. 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.

Cylinder Head Camshaft Journal Caps Installation Sequence, LH Side:

With LH cylinder head rocker arms installed, align LH cylinder head camshaft end play using thrust caps as a reference. Then tighten LH cylinder head camshaft journal cap bolts in sequence shown to 8-12 Nm (71-106 inch lbs.) leaving thrust caps loose.
61. 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 Nm (71-106 inch lbs.)

62. CAUTION: Rotating the crankshaft in a counter clockwise direction may cause timing chains to bind and cause engine damage.

CAUTION: Use care to prevent camshaft sprockets from jumping timing chain links. If timing jumps, the timing chains must be removed and installed again or engine damage may occur.

Rotate crankshaft clockwise 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).

63. 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: Make sure rocker arms are installed in their original locations.

Lubricate rocker arms by immersing rocker arm in 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.

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

Cylinder Head Camshaft Journal Cap Installation Sequence, RH Side:

With RH cylinder head rocker arms installed, align RH cylinder head camshaft end play using thrust caps as reference. Then tighten RH cylinder head camshaft journal cap bolts in sequence shown to 8-12 Nm (71-106 inch lbs.) leaving thrust caps loose.

Timing Chain Index Marks:

65. 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 Nm (71-106 inch lbs.)