Part 1

Engine

Special Tool(s):

Material:

Engine Component View:

Assembly
All engines
1. Record the main bearing code found on the front of the engine block.

2. Record the main bearing code found on the back of the crankshaft.

3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart determine the required bearing grade for each main bearing.
^ Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
^ Read down the column below the engine main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 1 crankshaft main bearing.
^ As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is "2."
^ Repeat this process for the remaining 4 main bearings.

4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing.

5. 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 with clean engine oil and install the crankshaft upper main bearings into the cylinder block.
6. Install the crankshaft onto the upper crankshaft thrust bearing and main bearings.

7. 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.

8. 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.

9. 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 10 jack screws against the cylinder block in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).

10. Install the 10 bolts and tighten in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 10 Nm (89 inch lbs.).
^ Stage 2: Tighten to 21 Nm (15 ft. lbs.).

11. Tighten the 10 bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.

12. Check piston-to-cylinder block and ring clearances.

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

NOTE: Make sure the piston arrow is facing forward.

NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.

Use the special tools to install the piston and connecting rod assemblies.
^ Lubricate the piston and ring with clean engine oil.
^ Lubricate the rod bearings with clean engine oil.
^ Rotate the crankshaft as necessary.

14. 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 special tools.

15. 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 make mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod cap, and install the 2 new bolts loosely.

16. Tighten the 16 bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 43 Nm (32 ft. lbs.).
^ Stage 2: Rotate an additional 90-120 degrees.

17. Position the oil pump and install the 3 bolts loosely. Tighten the bolts in the sequence shown.

Both cylinder heads

18. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seat correctly. Do not scratch the gasket.

NOTE: RH head gasket shown, LH head gasket similar.

Install the head gasket over the dowel pins.

19. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.

CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing of the cylinder head during cylinder head installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.

NOTE: RH cylinder head shown, LH cylinder head similar.

Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.

20. Tighten the 10 cylinder head bolts in 6 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).
^ Stage 3: Loosen a minimum of one full turn (360 degrees).
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees (1/4 turn).
^ Stage 6: Tighten an additional 90 degrees (1/4 turn).

21. Remove the special tools from both ends of the cylinder head.

22. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.

Install the 16 hydraulic lash adjusters in their original locations.

23. NOTE: Lubricate the O-ring seal with clean engine oil.

Install a new O-ring seal on the oil level indicator tube and install the oil level indicator tube and bolt.
^ Tighten to 10 Nm (89 inch lbs.).

24. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 new nuts.
^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown.

25. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 new nuts.
^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown.

Engines with ratcheting timing chain tensioners

26. 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.

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using an edge or a vise.

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

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

29. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
^ Remove the tensioner from the vise.

Engines with non-ratcheting timing chain tensioners

30. CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body or permanent compression of the seal bead, will require replacement of the tensioner.

Inspect the RH and LH timing chain tensioners.
^ Install new tensioners as necessary.

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

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using a vise.

32. Install a retaining clip on the tensioner to hold the plunger in during installation.

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

34. Using the special tool, position the crankshaft.
^ Remove the special tool after crankshaft positioning.

35. Install the crankshaft sprocket, making sure the flange faces forward.

36. Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the 2 LH bolts to 10 Nm (89 inch lbs.).
3. Position the RH timing chain guide.
4. Install and tighten the 2 RH bolts to 10 Nm (89 inch lbs.).

37. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.

38. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

39. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

40. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

Engines with ratcheting timing chain tensioners
41. Remove the retaining clip from the LH timing chain tensioner.

Engines with non-ratcheting timing chain tensioners
42. Remove the retaining clip from the LH timing chain tensioner.

All engines
43. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

44. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

45. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

Engines with ratcheting timing chain tensioners
46. Remove the retaining clip from the RH timing chain tensioner.

Engines with non-ratcheting timing chain tensioners
47. Remove the retaining clip from the RH timing chain tensioner.

All engines
48. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.

49. Rotate and camshaft until the lobe is in the up position.

50. Install the special tool between the valve spring coil to prevent valve stem seal damage.

51. NOTE: Lubricate the camshaft roller followers using clean engine oil.

NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.

Install the 16 camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the 16 camshaft roller followers in their original locations.

52. Remove the special tool.

53. Install all 8 spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).

54. Install the crankshaft sensor ring.

55. NOTE: RH timing chain removed for clarity.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. 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 a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.

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

57. Tighten the 15 front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).

58. NOTE: RH shown, LH similar.

Install the RH and LH engine mounts and the 6 bolts.
^ Tighten to 70 Nm (52 ft. lbs.).