Installation

1. Remove crankshaft main bearings from cylinder block and main bearing caps.

NOTE: If connecting rod bearings crankshaft main bearings and crankshaft thrust main bearings are to be reused, they should be identified to make sure that they are installed in their original positions.

2. Remove connecting rod bearings from the connecting rods and caps.
3. Inspect all machined surfaces on the crankshaft for nicks, scratches, scores, etc., which could cause premature bearing wear. Lightly stone all such surfaces.
4. If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize crankshaft main bearings.
5. Place upper crankshaft main bearings in position in the bores with the tang fitted in the slot provided.

CAUTION: Make sure crankshaft main bearings and bearing bores are clean. Foreign material under the crankshaft main bearings will distort the crankshaft main bearing and cause a failure.

6. Install lower crankshaft main bearings in main bearing caps.
7. Carefully lower crankshaft into place.
8. Check the clearance of each crankshaft main bearing. Select fit the crankshaft main bearings for proper clearance.
9. After crankshaft main bearings have been fitted, apply a light coat of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to the journals, bearings and crankshaft rear oil seal surface. Install all bearing caps. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to gap between rear crankshaft main bearing and cylinder block. Take care to keep silicone sealer from parting surfaces between cylinder block and cap.

NOTE: Make sure main crankshaft bearing caps are installed in their original positions and orientation.





10. Lubricate the journal with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install the thrust bearing cap with the bolts finger-tight. Pry the crankshaft forward against the thrust surface of the upper half of the crankshaft thrust main bearing. Hold the crankshaft cap to the rear. This will align the thrust surfaces of both halves of the crankshaft thrust main bearing. Retain the forward pressure on the crankshaft.
11. Check crankshaft end play.
12. If end play exceeds specification, replace upper and lower crankshaft thrust main bearings. If the end play is less than specification, inspect thrust bearing faces for damage, dirt or improper alignment. Install crankshaft thrust main bearings and align the faces. Recheck end play.
13. Install new connecting rod bearings in the connecting rods and caps. Check the clearance of each connecting rod bearing.
14. If connecting rod bearing clearances are to specification, apply a light coat of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to the journals and connecting rod bearings.
15. Turn the crankshaft throw to the bottom of the stroke. Push the piston all the way down until the connecting rod bearing seats on the crankshaft journal.
16. Install lower connecting rod bearing and connecting rod cap.
17. After piston and connecting rods have been installed, check connecting rod crankshaft journal side clearance.
18. Turn engine on the workstand so that the front end is up. Install timing chain, crankshaft sprocket and camshaft sprocket, engine front cover, new crankshaft front seal and crankshaft pulley and damper. Turn engine on the workstand so that the rear end is up. Install crankshaft rear oil seal.
19. Clean oil pan, oil pump and oil pump screen cover and tube.
20. Prime oil pump by filling the inlet opening with oil and rotating the oil pump intermediate shaft until oil emerges from the outlet opening. Install oil pump, oil pump screen cover and tube and oil pan.
21. Position flywheel on the crankshaft. Tighten to 73-87 Nm (54-64 ft. lbs.).
22. Turn engine on the workstand so that the engine is in the normal upright position. Install drive belt tensioner. Install drive belt.
23. Remove engine from the workstand. Install engine.