Installation

1. Lubricate and install crankshaft main bearings into cylinder blocks. Install crankshaft main bearings and crankshaft thrust main bearing into main bearing caps.

NOTE: All sealing surfaces must be clean and free of chips, dirt, paint and foreign material. Also, make sure oil passages are clear.

2. Install crankshaft into cylinder blocks.
3. Push crankshaft rearwards. Lubricate and install upper crankshaft thrust washer, by rolling the crankshaft thrust washer onto machined shelf between rear side of No. 5 bulkhead and thrust surface of crankshaft. Make sure coated side of crankshaft thrust washer with three 5 mm wide oil grooves faces the crankshaft thrust surface.





4. Install main bearing caps. Tap main bearing caps with a brass hammer to seat caps properly.

NOTE: Crankshaft main bearing cap adjusting screws must be bottomed on main bearing caps prior to installation of main bearing cap.





5. Push crankshaft forward using a prybar or similar tool to seat crankshaft thrust main bearing and crankshaft thrust washer.
6. With crankshaft pushed forward, install pry bars or similar tools to push both RH and LH front edges of No. 5 main bearing cap rearward and position the lower crankshaft thrust main bearing rear face properly against the thrust face of the crankshaft.

NOTE: No. 5 main bearing cap must be seated until the main bearing cap bolts are fully tightened as described below.





7. Tighten new main bearing cap bolts one through ten in two steps as follows:
a. Tighten bolts in sequence to 37-43 Nm (28-31 ft. lbs.).
b. Rotate bolts in sequence an additional 85-95 degrees.

CAUTION: Main bearing bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.

8. Tighten crankshaft main bearing cap adjusting screws 11 through 20 in two steps as follows:
a. Tighten crankshaft main bearing cap adjusting screws in sequence to 5 Nm (44 inch lbs.).
b. Tighten crankshaft main bearing cap adjusting screws in sequence to 9-11 Nm (80-97 inch lbs.).

9. Tighten main bearing cap side bolts 21 through 30 in two steps as follows:
a. Tighten main bearing cap side bolts in sequence to 10 Nm (7 ft. lbs.).
b. Tighten main bearing cap side bolts in sequence to 19-23 Nm (14-17 ft. lbs.).





10. Check crankshaft end play in both directions as shown.

NOTE: Pry against number two main bearing cap.





11. Apply a 2.0 mm (0.08 inch) continuous bead of Anaerobic Gasket Compound Sealer or equivalent meeting Ford specification WSK-M2G348-A9 to cylinder blocks as shown.

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 residue that may interfere with the sealer's ability to adhere.
^ The crankshaft rear oil seal retainer must be installed and the bolts tightened to specification within five minutes of sealer application.

Rear Oil Seal Retainer Tightening Sequence:

12. Install crankshaft rear oil seal retainer to cylinder blocks. Tighten six bolts in sequence to 8-12 Nm (71-106 inch lbs.).





13. Using Rear Crankshaft Seal Adapter T95P-6701-OH and Rear Crankshaft Seal Replacer T95P-6701-BH, install crankshaft rear oil seal (6701), if removed.
14. Using Rear Crankshaft Slinger Replacer T95P-6701-CH, replace crankshaft oil slinger (6310), if removed.
15. Turn crankshaft until the crankshaft throw is at bottom of stroke. Install upper connecting rod bearing onto connecting rod. Lubricate connecting rod bearing and crankshaft with clean engine oil.
16. Install connecting rod cap and lower connecting rod bearing. Alternately tighten new connecting rod cap bolts in several passes to obtain 40-45 Nm (30-33 ft. lbs.) and rotate connecting rod bolts an additional 85-95 degrees. After installation rotate crankshaft to ensure smooth operation.

CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Pull piston down until connecting rod bearing seats on crankshaft journal.

NOTE: Due to the use of a connecting rod joint face surface, the connecting rod cap must be properly aligned to the connecting rod. The connecting rod and connecting rod cap bearing tangs should be located on the same side of the connecting rod.





17. Check connecting rod side clearance using Rotunda Dial Indicator with Bracketry TOOL-4201-C or equivalent. Clearance should be 0.15-0.45 mm (0.006-0.0177 inch). If side clearance is greater than maximum service limit of 0.50 mm (0.020 inch), replace connecting rods and/or crankshaft.





18. Install oil pump and oil pump screen cover and tube.

NOTE: Install new O-ring on oil pump screen cover and tube and start all bolts on oil pump and oil pump screen cover and tube before tightening.

19. Rotate crankshaft to position as shown.

CAUTION: Failure to position crankshaft as shown will cause damage to pistons and/or valve train components.

NOTE: With crankshaft in this position, no piston will be at top dead center (TDC).

20. Rotate crankshaft clockwise 45 degrees. This will position crankshaft at top dead center (TDC) No. 1.

CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as top dead center (TDC) No. 1.

21. Install camshafts.
22. Install timing chains.
23. Replace crankshaft front seal (6700) in engine front cover if required.





24. Install engine front cover.





25. Install crankshaft position sensor and camshaft position sensors into engine front cover and tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).





26. Reconnect fuel charging wiring to crankshaft position sensor and camshaft position sensor.





27. Install oil pan with new oil pan gasket. Tighten bolts to 25-35 Nm (19-25 ft. lbs.) in no more than four minutes after applying sealer.





28. Install crankshaft pulley using Crankshaft Damper Replacer T74P-6316-B.

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 residue that may interfere with the sealer's ability to adhere.
^ Silicone Gasket F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 must be applied to crankshaft keyway prior to installing crankshaft pulley.

29. Install crankshaft pulley bolt and crankshaft pulley retaining washer. Tighten in four steps:
a. Tighten to 90 Nm (67 ft. lbs.).
b. Loosen one full turn.
c. Tighten to 50 Nm (37 ft. lbs.).
d. Tighten an additional 90 degrees.





30. Install RH and LH valve cover gaskets (6584). Tighten studs and bolts to 8-12 Nm (71-106 inch lbs.).





31. Install new oil bypass filter.
32. Install drive belt idler pulley and drive belt tensioner with ignition coils and tighten seven nuts to 20-30 Nm (15-22 ft. lbs.).
33. Install water pump pulley and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
34. Install accessory drive belt.
35. Install flywheel and tighten six bolts to 73-87 Nm (54-64 ft. lbs.).
36. Install ignition wires.
37. Install engine.