Installation

1. Lightly oil all bolt and stud bolt threads with clean engine oil meeting Ford specification WSS-M2C153-G before installation except those specifying special sealant.

Lubricate cylinder wall and piston with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting For specification ESR-M99C80-A.

2. Install a 50 mm (2 inch) piece of 3/8 inch fuel hose (or similar protector) on the connecting rod studs.

Piston & Rod Assembly:

3. Install piston using Rotunda Piston Ring Compressor 014-00290 or equivalent.

Make sure notch in piston dome faces the front of engine and machine locating boss is facing RH side of engine.

CAUTION: As piston is tapped into bore with a wooden hammer handle, guide connecting rod onto crankshaft journal to avoid damage to bearing surfaces.

NOTE:
- Connecting rod and cap are not identified to cylinder position.
- Install the pistons in the same cylinders from which they were removed or to which they were fitted. The connecting rod and caps are identified with matching correlation letters. Letters on the connecting rod and cap must be on the same side when installed in the cylinder bore. If a connecting rod is transposed from one cylinder block or cylinder to another, new connecting rod bearings should be fitted.

4. Check connecting rod bearing clearance.
5. Lubricate bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
6. Make sure connecting rod is seated on crankshaft journal. Install connecting rod cap. Tighten the cap retaining nuts to 31-39 Nm (23-28 ft. lbs.).
7. If necessary, check connecting rod side clearance.
8. Install oil pump and oil pump intermediate shaft. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
9. Install oil pan.
10. Install cylinder heads.
11. Install lower intake manifold.
12. Install valve covers and upper intake manifold.
13. Fill crankcase to proper level with clean engine oil X0-5W30 or equivalent meeting Ford specification WSS-M2C153-G.
14. Fill engine cooling system with specified coolant.
15. Start engine and check for oil, exhaust and coolant leaks.
16. Check and, if necessary, adjust accelerator cable and speed control actuator cable.