Steps 1-61

Special Tools:

All Engines

1. CAUTION: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

Lubricate and install the crankshaft upper main bearings into the cylinder block.
Use Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

2. Install the crankshaft onto the upper crankshaft thrust bearing and main bearings.

3. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).

Install the rear main bearing cap.

4. Install the crankshaft lower main bearings, thrust bearing and thrust washer into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or dead-blow hammer.

5. NOTE: The jack screws are a part of the main bearing cap assembly, and are screwed into the main caps, not the cylinder block.

Back out the jack screws against the cylinder block in two stages, in the sequence shown.
1 Stage 1: Tighten to 5 Nm (44.6 inch lbs.)
2 Stage 2: Tighten to 9-11 Nm (80-97 inch lbs.)

6. Install the bolts and tighten in two stages in the sequence shown.
Stage 1: Tighten to 10 Nm (89.2 inch lbs.).
Stage 2: Tighten to 19-23 Nm (14-17 ft. lbs.).

7. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: Stages 8, 9 and 10 are for all eight connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.

Use the Connecting Rod Guide Tool and the Piston Ring Compressor to install the connecting rod with upper connecting rod bearing in place.

8. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Guide Tool.

9. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated properly.

Position the lower bearing and connecting rod, and install the new bolts loosely.

10. Tighten the bolts in two stages, using the sequence shown.
Stage 1: 40-45 Nm (30-33 ft. lbs.).
Stage 2: Rotate 90-120 degrees.

11. Install the RH engine mount and the three bolts.

12. Install the oil filter adapter.

13. Install the LH engine mount and the bolts.

14. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.

15. CAUTION: Make sure all coolant residue and debris are cleaned from the block surface and cylinder bore.

NOTE: RH is shown; LH is similar.

Position the (A) head gasket over the (B) dowel pins.

16. Rotate the crankshaft until the crankshaft keyway points toward the top of the engine (12 o'clock).

17. NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: RH is shown; LH is similar.

Position the (A) cylinder head over the dowels on the (B) head gasket and install the (C) bolts loosely.

18. NOTE: RH is shown, LH is similar

Tighten the bolts in three stages, in the sequence shown.
Stage 1: 37-43 Nm (27-32 ft. lbs.)
Stage 2: Rotate 85-95 degrees
Stage 3: Rotate 85-95 degrees

19. NOTE: Lubricate the O-ring with Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the oil level indicator tube
^ Install a new O-ring on the oil level indicator tube.
^ Install the oil level indicator tube.
^ Install the bolt.

20. NOTE: LH is shown; RH is similar

Install the LH exhaust manifold.
^ Install the exhaust manifold gasket.
^ Install the exhaust manifold.
^ Tighten the nuts in sequence.

21. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Compress the tensioner plunger, using an edge of a vise.

22. Using a small screwdriver or pick, push back and hold the ratchet mechanism.

23. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

24. Install a paper clip into the hole in the tensioner housing to hold in the ratchet assembly and plunger during installation.

25. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.

26. Remove the tensioner from the vise.

27. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install and tighten the bolts.
3 Position the RH timing chain guide.
4 Install and tighten the RH bolts.

28. Install the timing chain and crankshaft sprockets.
1 Slide the (A) crankshaft sprocket onto the (B) crankshaft, aligning the copper link on the timing chains with the dot on the crankshaft sprocket.
2 Position the timing chains over the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket.

29. Make sure that the (A) copper marks on the timing chains are lined up with the corresponding dots on the crankshaft sprockets and camshaft sprockets.

30. Use the camshaft position tool to make sure that the (A) camshaft sprocket keyway is 90 degrees from the (B) valve cover mounting surface.

31. Make sure that the (A) RH crankshaft sprocket is on the front of the (B) LH crankshaft sprocket with the long hubs facing each other.

32. Position the LH and RH timing chain tensioner arm on the dowel pins.

33. Position the RH timing chain tensioner and install the timing chain tensioner bolts.

34. Position the LH timing chain tensioner and install the bolts.

35. Remove both the paper clips from the timing chain tensioners.

36. Remove the (A) Camshaft Positioning Tool and the Camshaft Positioning Tool Adapters from the (B) camshaft.

37. Position the crankshaft sensor ring on the crankshaft.

38. NOTE: If the bolt is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness or four minutes whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone along the head-to-block surface and the oil pan-to-block surface.
Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4.

39. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.

40. Tighten the fasteners in two stages. Refer to the above illustration.
Stage 1: Tighten fasteners 1 through 7 to 20-30 Nm (15-22 ft. lbs.).
Stage 2: Tighten fasteners 6 through 15 to, 55 Nm (30-41 ft. lbs.).

41. Install the oil pump screen cover and tube spacer.

42. Position the oil pump screen cover and tube, and install the bolts.

43. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness or four minutes whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply the silicone at the rear oil seal retainer to cylinder block sealing surface.
Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4.

44. Apply silicone at the front cover to cylinder block sealing surface.
Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4.

45. Position the Oil pan gasket, the oil pan and the bolts on the engine.

46. Tighten the bolts in three stages, in the sequence shown.
Stage 1: 2 Nm (18 inch lbs.)
Stage 2: 20 Nm (15 ft. lbs.)
Stage 3: Rotate 60 degrees

47. Position the belt idler pulley and install the bolt.

48. CAUTION: Do not rotate the water pump housing once the water pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Install the water pump.
1 Lubricate the new O-ring seal using Premium Cooling System Fluid E2FZ-19549-AA, in Oregon F5FZ-19549-CC, in Canada, Motorcraft CXC-8-B Recycled Coolant, or equivalent that meets Ford specification ESE-M971344-A and/or WSS-M971344-1).
2 Position the water pump into the engine block.
3 Install the bolts.

49. Lubricate the (A) engine front cover and the (B) front oil seal inner lip.
Use Ford Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

50. Use the (A) Crankshaft Seal Installer/Aligner to install the (B) crankshaft front seal into the (C) engine front cover.

51. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone to the Woodruff key slot on the crankshaft pulley. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4.

52. Use the Crankshaft Damper Replacer to install the crankshaft pulley.

53. Tighten the crankshaft pulley bolt in four stages.
Stage 1: 90 Nm (66 ft. lbs.)
Stage 2: Loosen 360 degrees
Stage 3: 47-53 Nm (35-39 ft. lbs.)
Stage 4: Rotate 85-90 degrees

54. Position the water pump pulley on the water pump and install the bolts.
55. Lower the vehicle.

56. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone in two places where the engine front cover meets the cylinder head.
Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4.

57. Install the gasket into the valve cover and position the left valve cover on the cylinder head and tighten the bolts in the sequence shown.

58. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone in two places where the engine front cover meets the cylinder head.
Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4.

59. Position the right valve cover and gasket and tighten the bolts in the sequence shown.

60. Install new intake manifold gaskets.

Gasoline Engines

61. Install the intake manifold and hand-tighten the bolts at the locations shown.