Removal and Installation

Part 1 Of 2:

Part 2 Of 2:

REMOVAL
1. Remove engine from vehicle.
2. Mount engine in a suitable work stand. Drain crankcase and cylinder block cooling jackets.
3. Disconnect ignition wires from the spark plugs (12405).
4. Remove spark plugs.
5. Remove oil pan (6675) and oil pump screen cover and tube (6622).
6. Remove crankshaft pulley and vibration damper.
7. Remove engine front cover (6019) and water pump (8501) as an assembly.
8. Remove timing chain tensioner.
9. Remove crankshaft sprocket (6306), camshaft sprocket (6256) and timing chain.
10. Remove flywheel (6375) and rear engine plate (7007). Refer to Transmission and Drivetrain.

NOTE: Turn crankshaft (6303) as necessary to position connecting rod (6200) in the low point of travel before removing connecting rod cap. Each connecting rod cap should be identified so it can be installed in its original position during assembly.

11. Remove connecting rod caps.

CAUTION: Use care to make sure crankshaft journals are not damaged while pushing pistons into bores.

12. Push piston (6108) into cylinder block bore after removing connecting rod cap.
13. Remove crankshaft main bearing caps.

NOTE: Handle crankshaft with care to prevent possible damage to finished bearing surfaces.

14. Carefully lift crankshaft out of cylinder block (6010) to prevent damage to bearing surfaces.
15. Remove crankshaft rear oil seal (6701) and discard.

CAUTION: Because the crankshaft incorporates deep rolling of the main and pin journal fillets, journal refinishing is limited to 0.25 mm (0.010 inch) undersize standard journal dimensions. Further crankshaft main journal refinishing may result in fatigue failure of the crankshaft.

16. Clean and inspect crankshaft and related components.

INSTALLATION

CAUTION: Contaminants left on bearing surfaces will cause damage to the crankshaft journals.

NOTE: Lightly oil all bolts and stud threads before installation with clean engine oil meeting Ford specification WSS-M2C153-F.

1. Make sure all bearing surfaces and crankshaft main bearings (6333) are clean.
2. If crankshaft main bearing journals have been refinished to definite undersize:
a. Remove crankshaft main bearings from cylinder block and main bearing caps.
b. Loosen the lower intake manifold retaining bolts and support brackets prior to installing crankshaft main bearings or measuring bearing clearances.
c. Install new crankshaft main bearings. Make sure tabs on crankshaft main bearings engage slots in the main cap and cylinder block.
d. Check main bearing fit/oil clearance. Fitting/Oil Clearance Check
3. Make sure crankshaft rear oil seal groove in cylinder block and main bearing cap is clean.
4. Carefully lower crankshaft into position in cylinder block. Be careful not to damage crankshaft thrust main bearing (6337).
5. Clean sealing surfaces with Metal Parts Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealers ability to adhere.

NOTE: When using silicone sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up and its sealing effectiveness may be reduced.

6. Apply a 3 mm (0.125 inch) bead of Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 to rear main bearing cap-to-cylinder block parting line.
7. Lubricate bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install main bearing caps and retaining bolts.
8. Tighten main bearing cap retaining bolts as follows:

NOTE: Do not jam the prybar into position. Carefully tap on the prybar until it holds crankshaft toward front of engine.

a. Wedge a prybar between cylinder block web and crankshaft cheek in front of the No.3 crankshaft main bearing.
b. Tighten main bearing cap retaining bolts in two steps in sequence.
Step 1 ... Tighten to 50 Nm (37 ft. lbs.).
Step 2 ... Rotate an additional 115-125°.
c. Remove prybar.
9. Check crankshaft end play. End Play
10. Install crankshaft rear oil seal.
11. If crankshaft connecting rod journals have been refinished to a definite undersize, remove connecting rod bearings (6211) from connecting rods and connecting rod caps.
12. Install new connecting rod bearings. Make sure tabs on connecting rod bearings securely engage the slots in connecting rod and cap.
13. Rotate crankshaft as necessary to bring each crankshaft throw to lowest point of travel. Pull piston downward until connecting rod bearing seats on crankshaft and install connecting rod caps.
14. Perform the following on EACH connecting rod cap.

NOTE: As each clearance check is completed, lubricate bearing surfaces with Engine Assembly Lubricant before installing connecting rod cap.

A. Check connecting rod bearing oil clearance. Component Tests and General Diagnostics
B. Tighten retaining bolts in three steps.
Step 1 ... Tighten to 20-25 Nm (15-18 ft. lbs.).
Step 2 ... Tighten to 40-45 Nm (30-33 ft. lbs.).
Step 3 ... Rotate an additional 90-120°.

15. Install timing chain and engine front cover with water pump.
16. Install camshaft position sensor (CMP)(6B288).
17. Install oil pan.
18. Install rear engine plate and flywheel.
19. Install spark plugs. Refer to Powertrain Management.
20. Connect ignition wires to spark plugs.
21. Install engine in the vehicle.