Removal and Installation

REMOVAL





NOTE: This procedure will remove and install the crankshaft (6303) with the engine REMOVED from the vehicle.

1. Remove ignition wires.
2. Remove six flywheel retaining bolts and remove flywheel (6375) from crankshaft.
3. Remove accessory accessory drive belt (8620).
4. Remove water pump pulley (8509).
5. Remove drive belt idler pulley (8679) and ignition coil mounting brackets with ignition coils.(12029) from engine front cover (6019).
6. Remove oil bypass filter (6714).
7. Remove RH and LH valve covers (6582) from cylinder heads (6049).
8. Remove crankshaft pulley (6312).
9. Remove oil pan (6675) and oil pan gasket (6710).
10. Remove engine front cover.

NOTE: This will position all pistons (6108) below top of cylinder block deck face.

11. Position crankshaft on top dead center (TDC.) No. 1.
12. Remove timing chains.
13. Remove oil pump screen cover and tube (6622) and oil pump (6600).
14. Remove crankshaft oil slinger (6310) and crankshaft rear oil seal (6701) using Rear Crankshaft Slinger Remover T95P-6701-AH, Rear Crankshaft Seal Remover T95P-6701-EH and Slide Hammer T50T-100-A.
15. Remove crankshaft rear oil seal retainer (6335).

NOTE: Connecting rods (6200), connecting rod caps and connecting rod bearings (6211) should be numbered to make sure they are assembled in their original positions.

16. Turn crankshaft until connecting rod cap to be removed is accessible. Identify the connecting rods, connecting rod caps and connecting rod bearings for cylinder position.
17. Remove the connecting rod cap and lower and upper connecting rod bearings. Keep cap and connecting rod bearings together. Use care to prevent damage to the bearing, cylinder bore and crankshaft surfaces.

CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or engine damage may occur.

18. Connecting rod bolts (6214) are retained in the bolt hole with a light press fit. The connecting rod bolts have been torqued to yield at least twice and must be discarded. Use a hammer and punch to drive connecting rod bolts from connecting rod can.
19. Remove horizontal main cap side bolts from cylinder block (6010).
20. Loosen crankshaft main bearing cap adjusting screws (6C360) on bearing main caps.
21. Remove bearing main cap retaining bolts. These are torque-to-yield bolts and cannot be reused.

NOTE: The location of the main bearing caps and the crankshaft main bearings (6333) should be identified. When the engine is assembled crankshaft main bearings which are to be reused should be installed in their original positions.

22. Remove each main bearing cap and lower crankshaft main bearing and crankshaft thrust main bearing (6337). Keep each cap, lower crankshaft main bearing and crankshaft thrust main bearing together.

CAUTION: When removing the crankshaft, use care not to damage any of the bearing surfaces on the crankshaft.

23. Remove crankshaft.
24. If required, replace crankshaft main bearings, crankshaft thrust main bearing and crankshaft thrust washer (6334).

INSTALLATION

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

1. Lubricate with clean engine oil meeting Ford specification WSS-M2C910-A1 and install crankshaft main bearings into cylinder block. Install crankshaft main bearings and crankshaft thrust main bearing into main bearing caps.

CAUTION: Use care when installing crankshaft or damage to the bearing corners or surfaces may occur.

2. Install crankshaft into cylinder block.
3. Push crankshaft rearward. 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.

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





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





5. Push crankshaft forward using a pry bar or similar tool so that crankshaft thrust face is flush to number five bulkhead.

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

6. With crankshaft pushed forward, install prybars 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.

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





7. Tighten new main bearing cap bolts 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°.
8. Tighten crankshaft main bearing cap adjusting screws in sequence to 9-11 Nm (80-97 inch lbs.).
9. Tighten main bearing cap side bolts in sequence to 19-23 Nm (14-17 ft. lbs.).

NOTE: Pry against number two main bearing cap.





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

NOTE: Crankshaft rear oil seal retainer must be installed and bolts tightened to specification within five minutes of sealer application.





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 block as shown.

Rear Oil Seal Retainer Tightening Sequence:

12. Install crankshaft rear oil seal retainer to cylinder block and tighten six bolts in sequence to 8-12 Nm (71-106 inch lbs.).
13. Using Rear Seal Replacer Adapter T95P-6701-DH, Rear Main Seal Replacer T95P-6701-BH and Rear Slinger Replacer T95P-6701-CH, install crankshaft rear oil seal and crankshaft oil slinger.
14. 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 meeting Ford specification WSS-M2C910-A1.

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 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.

15. Install connecting rod cap and lower connecting rod bearing and alternately tighten new connecting rod cap bolts in three steps:
a. Tighten to 20-25 Nm (15-18 ft. lbs.).
b. Tighten to 40-45 Nm (30-33 ft. lbs.).
c. Tighten an additional 90-120°. After installation, rotate crankshaft to make sure smooth operation.
16. Check connecting rod side clearance using 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.

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





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

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.).





18. Rotate crankshaft to position as shown.

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





19. Rotate crankshaft clockwise 45°. This will position crankshaft at top dead center (TDC.) No. 1.
20. Install timing chains.
21. Install oil pan with new oil pan gasket. Tighten bolts to 20 Nm (14 ft. lbs.) and then an additional 60° in no more than four minutes after applying sealer.
22. Replace crankshaft front seal (6700) in engine front cover.
23. Install engine front cover.

NOTE: 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.

24. Install crankshaft pulley using Crankshaft Damper Replacer T74P-6316-B.
25. Install crankshaft pulley bolt (6A340) and crankshaft pulley retaining washer (6378). Tighten in four steps:
a. Tighten to 90 Nm (66 ft. lbs.).
b. Loosen one full turn (360°).
c. Tighten to 47-53 Nm (35-39 ft. lbs.).
d. Tighten an additional 85-95°.
26. Install RH and LH valve covers. Tighten studs and bolts to 8-12 Nm (71-106 inch lbs.).
27. Install new oil bypass filter.
28. Install drive belt idler pulley, and ignition coil mounting brackets with ignition coils and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
29. Install water pump pulley and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
30. Install accessory accessory drive belt.
31. Install flywheel and tighten six bolts to 73-87 Nm (54-64 ft. lbs.).
32. Install ignition wires.
33. Install engine.