Assembly

1. Lubricate and install crankshaft main bearings into cylinder blocks. Install crankshaft main bearings and crankshaft thrust main bearing (6337) into main bearing caps.

NOTE: Before assembling cylinder blocks, all sealing surfaces must be clean and free of chips, dirt, paint and foreign material. Also, make sure coolant and oil passages are clear.

2. Install crankshaft into cylinder blocks.








3. Push crankshaft rearward. Lubricate and install upper crankshaft thrust washer (6334), by rolling the crankshaft thrust washer onto machined shelf between rear side of No. 5 bulkhead and thrust face surface of crankshaft. Make sure coated side of crankshaft thrust washer with three 5 mm wide oil grooves is facing 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 cap 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 85-95 degrees.

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

9. 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 bolts tightened to specification within five minutes of sealer application.





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








13. Using Rear Crankshaft Seal Replacer Adapters T95P-6701-BH, Rear Main Seal Replacer T95P-6701-DH and Rear Crankshaft Slinger Replacer T95P-6701-CH, install crankshaft rear oil seal (6701) and crankshaft oil slinger (6310).
14. Coat piston bores, pistons, rings, crankshaft journal and bearing surfaces with clean engine oil meeting Ford specification WSS-M2C153-F.





15. Turn crankshaft until the crankshaft throw is at bottom of stroke. Install correctly numbered pistons, connecting rods and upper connecting rod bearings with Piston Ring Compressor Tool D81L-6002-C or equivalent and a suitable connecting rod guide tool or equivalent.

NOTE:
^ Make sure piston ring gaps are rotated 30 degrees apart.
^ Notch on piston to front of engine.

16. Push piston down until connecting rod bearing seats on crankshaft.

CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod.

17. Install connecting rod cap and lower connecting rod bearing and 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 90-120 degrees. After installation, rotate crankshaft to verify smooth operation.

NOTE: Due to the use of a cracked 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.





18. 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.





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

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

20. If cylinder heads are to be serviced, refer to Cylinder Head Assembly.

NOTE: Make sure cylinder heads are installed in their original positions.





21. Position new head gaskets on cylinder heads.

CAUTION: Do not use sandpaper coarser than 600 grit. Damage to sealing surfaces may occur.

NOTE:
^ Clean cylinder head gasket surface with a toluene-based paint thinner or gasket remover. If gasket material remains on head after cleaning, use a 600 grit sandpaper to remove remaining material.
^ RH and LH head gaskets are not interchangeable.





22. 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).





23. Position cylinder heads on cylinder blocks. Use Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A to prevent crankshafts from rotating.

CAUTION: Use care when positioning cylinder heads. Damage to cylinder blocks and/or cylinder heads may result.





24. Tighten new cylinder head bolts as follows:
a. Tighten head bolts in sequence to 37-43 Nm (28-31 ft. lbs.).
b. Rotate head bolts in sequence 85-95 degrees.
c. Loosen head bolts a minimum of one full turn (360 degrees).
d. Retighten head bolts in sequence to 37-43 Nm (28-31 ft. lbs.).
e. Rotate head bolts in sequence 85-95 degrees.
f. Rotate head bolts in sequence an additional 85-95 degrees.

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

NOTE: Apply clean engine oil meeting Ford specification WSS-M2C 153-F to all head bolt spot-faces.





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

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

26. Install timing chains.
27. Replace crankshaft front seal (6700) in engine front cover if required.








28. Install engine front cover.





29. Install oil pan with new oil pan gasket. Tighten bolts to 20 Nm (14 ft. lbs.), then an additional 60 degrees in no more than four minutes after applying sealer.
30. Lubricate water pump housing gasket (8507) with Ford Premium Cooling System Fluid E2FZ-19549-AA (in Canada, Motorcraft CXC-8-B) or equivalent meeting Ford specification ESE-M97B44-A and install water pump and tighten retaining bolts to 20-30 Nm ( 15-22 ft. lbs.).





31. Install heater water hose.





32. Install crankshaft position sensor (CKP sensor)(6C315) and camshaft position sensors into engine front cover and tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).





33. 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 and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 must be applied to crankshaft keyway prior to installing crankshaft pulley.

34. 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 bolt to 50 Nm (37 ft. lbs.).
d. Tighten an additional 90 degrees.








35. Install RH and LH valve cover gaskets (6584). Tighten studs and bolts to 8-12 Nm (71-106 inch lbs.).
36. If intake manifold was disassembled, assemble as follows:
a. Install fuel injector Wrings (9C991) on fuel injectors with clean engine oil meeting Ford specification WSS-M2C153-F prior to assembly.
b. Install fuel injection supply manifold and fuel injectors and tighten four bolts to 8-12 Nm (71-106 inch lbs.).
c. Install engine coolant temperature sensor and water temperature indicator sender unit and tighten to 16-24 Nm (12-17 ft. lbs.).
d. Install idle air control valve and tighten bolts to 8-12 Nm (71-106 inch lbs.).
e. Install throttle body and throttle body adapter. Tighten bolts to 8-12 Nm (71-106 inch lbs.).

37. Position intake manifold gasket on cylinder heads.

NOTE: Align tabs on intake manifold gasket (9461) with holes in cylinder heads.

38. Install intake manifold. Tighten retaining bolts in sequence to 20-30 Nm (15-22 ft. lbs.).
39. Install water outlet connection O-ring and water hose connection. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).

NOTE: Water outlet connection bolts are also intake manifold retaining bolts.

40. Install oil filter adapter and tighten bolts to 20-30 Nm (15-22 ft. lbs.).





41. Install oil bypass filter.
42. Install LH exhaust manifold and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
43. Install RH exhaust manifold and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
44. Install drive belt idler pulley and drive belt tensioner with ignition coils and tighten seven nuts to 20-30 Nm (15-22 ft. lbs.).





45. Install A/C compressor and tighten three bolts to 20-30 Nm (15-22 ft. lbs.).
46. Install water pump pulley and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
47. Install generator and tighten generator-to-cylinder block retaining bolts to 20-30 Nm (15-22 ft. lbs.).
48. Install generator mounting bracket and tighten to 8-12 Nm (71-106 inch lbs.).
49. Install positive crankcase ventilation valve and front vapor hose.
50. Install flywheel to crankshaft and tighten six bolts to 73-87 Nm (56-64 ft. lbs.).








51. Install fuel charging wiring and connect all applicable wiring connectors.
52. Install spark plugs. Tighten to 9-20 Nm (80-177 inch lbs.).
53. Install ignition wires.