Steps 1-60
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 installation or replacement of fasteners, all threads and contact surfaces of fasteners must be lubricated with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
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 Nm (12-17 ft. lbs.)
- 1/2 Inch Pipe Plug: 22-32 Nm (17-23 ft. lbs.)
- 3/4 Inch Pipe Plug: 22-32 Nm(17-23 ft. lbs.)
3. NOTE: Using a hammer, lightly tap crankshaft key into crankshaft keyway.
With front of crankshaft supported by wood blocks, install crankshaft key into crankshaft keyway.
4. Using the journal code located on the cylinder block and crankshaft, select the proper grade of crankshaft main bearings as follows:
- Read the journal code on the cylinder block and the crankshaft counterweight.
- Main bearing journals are numbered J1, J2, J3, J4 and J5 from front to rear.
- Using the Select Fit Crankshaft 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.
5. Install upper crankshaft main bearings and upper crankshaft thrust washer into cylinder block. Insert crankshaft main bearing tang into slot in cylinder block. Install crankshaft thrust washers with oil groove against crankshaft.
6. CAUTION: When installing crankshaft, use care not to damage any crankshaft journal bearing surfaces.
Install crankshaft into cylinder block.
7. Lubricate upper crankshaft main bearings and crankshaft thrust washers with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G.
8. Install lower crankshaft main bearings and crankshaft thrust washers onto lower cylinder block.
9. Lubricate lower crankshaft main bearings and crankshaft thrust washer with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
10. Clean lower cylinder block-to-upper cylinder block sealing surfaces with a shop towel and Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A to remove all residues that may interfere with the sealer's ability to adhere.
11. Apply a 2-3 mm (0.070-0.118 inch) bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-IVI4G323-A6 to lower cylinder block sealing surface of cylinder block as illustrated.
12. Install lower cylinder block over cylinder block alignment dowels and onto upper cylinder block.
13. NOTE: Do not lubricate lower cylinder block-to-upper cylinder block retaining bolts.
Install all lower cylinder block-to-upper cylinder block retaining bolts.
14. NOTE: Tighten all lower cylinder block-to-upper cylinder block retaining bolts within six minutes of installing lower cylinder block onto upper cylinder block.
Tighten lower cylinder block-to-upper cylinder block retaining bolts in sequence, as follows:
- Tighten fasteners 1 through 10 to 22-28 Nm (17-20 ft. lbs.)
- Tighten fasteners 11 through 20 to 37-43 Nm (28-31 ft. lbs.)
- Rotate fasteners 1 through 20 an additional 85-95 degrees.
- Tighten fasteners 21 through 31 to 20-30 Nm (15-22 ft. lbs.)
15. Verify crankshaft rotates freely and does not bind. Clean any residual sealer from inside the cylinder block with a clean shop towel.
16. NOTE: Lubricate crankshaft flange and crankshaft rear oil seal bore inside diameter with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation of crankshaft rear oil seal.
Install crankshaft rear oil seal using Rear Main Seal Replacer 303-178 (T82L-6701-A) and Rear Crank Seal Replacer Adapters 303-384 (T91P-6701-A). Alternate bolt tightening to properly seat the crankshaft rear oil seal 0.5-0.0 mm (0.020-0.0 inch) flush to rear of cylinder block.
17. Check crankshaft end play in both directions as shown using Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent.
18. If disassembled, assemble piston, pin and rings onto connecting rods.
19. If being replaced, assemble new piston rings onto piston, pin and rings.
20. 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.
21. CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Push piston, pin and ring down until connecting rod bearing seats on crankshaft journal.
NOTE: Lubricate piston, pin and rings, piston rings, connecting rods and connecting rod bearings with Super Premium SAE 5W30 Motor Oil XO-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation.
NOTE: Install with front mark on piston, pin and ring to front of engine.
Turn crankshaft until crankshaft throw is at bottom of stroke. Install correctly numbered piston, pin and ring and connecting rod with Piston Ring Compressor 303-D032 (D81L-6002-C) or equivalent and Connecting Rod Guide Tool 303-462 (T94P-6136-AH).
22. 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 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 an additional 90-120 degrees.
23. After installation of each piston, pin and ring and connecting rod, rotate crankshaft to verify smooth operation.
24. Check connecting rod side clearance using Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent. Side clearance should be 0.15-0.30 mm (0.006-0.011 inch).
If connecting rod side clearance is greater than maximum service limit, replace connecting rod and/or crankshaft.
25. Rotate inner rotor of oil pump to align with flat on crankshaft.
26. Carefully install oil pump onto crankshaft until seated against cylinder block.
Fig. 19 Oil Pump Bolt Tightening Sequence:
27. Install oil pump retaining bolts and tighten in sequence to 9-13 Nm (80-115 inch lbs.)
28. Install oil pan baffle and oil pump screen cover and tube with a new oil pump inlet tube gasket. Tighten oil pump screen cover and tube retaining nuts to 8-14 Nm (71-123 inch lbs.)
29. Tighten five oil pan baffle retaining nuts to 14-25 Nm (11-19 ft. lbs.)
30. Turn engine right side up on engine stand.
31. Remove balance shaft rear bearing bore core plug from rear face of engine block.
32. Install Balance Shaft Rear Bearing Locator 303-555 (T96P-6A333-GH) into core plug bore using bolts provided.
33. Install rear bearing onto Balance Shaft Rear Bearing Replacer 303-5,61 (T96P-6A333-CH). Slide Balance Shaft Rear Bearing Aligner 303-552 (T96P-6A333-DH) onto replacer shaft. Position bearing at rear bearing bore and aligner into front bearing bore.
34. Install Balance Shaft Bearing Replacer Adapter 303-554 (T96P-6A333-FH) onto front face of engine block with bolts provided. Assemble Front Hub Remover/Replacer 204-069 (T81P-1104-C) to adapter. Push rear bearing into bore until seated against Balance Shaft Rear Bearing Locator 303-555 (T96P-6A333-GH). Remove rear Balance Shaft Rear Bearing Locator from rear face of engine block. Remove Front Hub Remover/Replacer from Balance Shaft Bearing Replacer Adapter.
35. NOTE: Use Impact Slide Hammer 100-001 (T50T-100-A) only as a handle to assist in balance shaft installation. Do not hammer balance shaft into position. Thread Balance Shaft Remover/Replacer 303-549 (T96P-6A333-AH) with Impact Slide Hammer into balance shaft. Carefully install balance shaft into rear bearing until seated. Remove slide hammer and adapter leaving balance shaft in place.
36. NOTE: Position flat on tool upward to clear flange on engine block.
Slide front balance shaft bearing over nose of balance shaft. Position Balance Shaft Front Bearing Replacer 303-553 (T96P-6A333-EH) against bearing. Assemble Front Hub Remover/Replacer to adapter. Push front bearing into bore until seated. Remove all tools.
37. NOTE: Balance shaft should rotate freely.
Install balance shaft holder with three bolts. Tighten to 21-30 Nm (16-22 ft. lbs.). Install balance shaft key into balance shaft.
38. Install engine balance shaft driven gear over balance shaft key onto balance shaft and secure with bolt. Tighten to 46-58 Nm (34-42 ft. lbs.)
39. Install core plug in rear face of block.
40. Install new ventilation case gaskets, ventilation case separator, ventilation case retainer bolts and nuts to cylinder block. Tighten bolts and nuts to 8-12 Nm (71-106 inch lbs.)
41. Install two knock sensors to cylinder block. Tighten to 36-52 Nm (27-38 ft. lbs.)
42. Connect engine control sensor extension wiring to knock sensors.
43. If disassembled, assemble cylinder heads.
44. 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.
45. 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.
46. 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 Bolt Tightening Sequence:
Install new torque-to-yield cylinder head retaining bolts and tighten in sequence, as follows:
- Tighten bolts to 27-32 Nm (20-23 ft. lbs.)
- Rotate bolts an additional 85-95 degrees.
Crankshaft & Oil Pump Timing Mark Alignment:
47. Rotate crankshaft to position No. 1 piston at top-dead-center (TDC) by aligning the crankshaft keyway groove with the oil pump mark.
48. NOTE: Make sure valve tappets are installed in their original locations.
Lubricate valve tappets with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G and install valve tappets to cylinder heads.
49. 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 Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Install timing chain /belt on intake and exhaust camshafts. Match sprocket and chain timing marks and install camshafts into cylinder heads with timing marks pointing up.
50. Apply a 2-3 mm (0.08-0.11 inch) bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to LH cylinder head intake camshaft journal cap.
51. NOTE: Make sure cylinder head camshaft journal caps are installed in their original positions.
LH Shown. RH Similar.:
Loosely install cylinder head camshaft journal caps and retaining bolts.
Camshaft Journal Cap Bolt Tightening Sequence:
52. Tighten camshaft journal cap retaining bolts in sequence, in two steps, as follows:
- First step, 7-12 Nm (62-106 inch lbs.)
- Second step, 16-21 Nm (12-15 ft. lbs.)
53. Install camshaft seal with Cam Seal Expander 303-342 (T89P-6256-B) and Cam Seal Replacer 303-341 (T89P-6256-A).
54. Install Cam Position Tools 303-543 (T96P-6256-AH) on LH intake cam and RH exhaust cam. Use existing cam chain tensioner bolts.
55. NOTE: Do not rotate crankshaft more than 45° counterclockwise or more than 90° clockwise from previously set No. 1 cylinder top-dead-center position. Valve-to-piston contact could occur.
Set No. 1 cylinder top-dead-center position by aligning crankshaft keyway with mark on oil pump.
Fig. 13 Engine Front Cover Installation:
56. Match sprocket and chain timing marks and install timing chain/belt with crankshaft, camshaft and balance shaft positioned as indicated.
57. Install camshaft sprocket on camshaft with camshaft sprocket bolt. Tighten camshaft sprocket bolt to 64-96 Nm (48-70 ft. lbs.)
58. 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.
(Part 1 Of 2):
Install compressed LH timing chain tensioner, timing chain tensioner arm, timing chain guide and retaining bolts onto cylinder block. Tighten timing chain/belt tensioner bolt pivot bolt to 34-53 Nm (25-39 ft. lbs.). Tighten timing chain tensioner retaining bolts to 18-27 Nm (14-20 ft. lbs.)
59. Remove Cam Position Tools 303-543 (T96P-6256-AH) and install timing chain tensioners with retaining bolts. Tighten retaining bolts to 8-12 Nm (71-108 inch lbs.)
60. Remove lock pin from timing chain tensioners.