Assembly

1. Align the piston cooling oil jet nozzle with the piston's taper cut-out.





Use Oil Jet Replacer T92C-6327-BH and Cross Bar Oil Jet Remover/Replacer T92C-6327-AH to install the piston cooling oil jets.





When pressing the piston cooling oil jets, use a minimum pressure of 3.2 KN (330 kgf). The piston cooling oil jets may come loose if they are not pressed in with enough force, or are not pressed in to the depth of 10.5-11 mm (0.413-0.433 inches).

2. Install the upper crankshaft main bearings and the crankshaft thrust bearings.
3. Install the crankshaft.
4. Install the lower crankshaft main bearings.





5. Measure the crankshaft main bearing cap bolt before reinstalling. If the crankshaft main bearing cap bolt is longer than 69mm (2.7 inches) then replace the crankshaft main bearing cap bolt with a new one.





Install the crankshaft main bearing caps. Tighten the crankshaft main bearing cap bolts in the sequence shown to 18-22 Nm (13-16 ft. lbs.), then turn each crankshaft main bearing cap bolt an additional 90 +/- 5 degrees.
6. Use Piston Ring Compressor D81L-6002-C, or equivalent, to install the pistons.





7. Use the alignment marks for proper installation.





Measure the length of each connecting rod bolt before reinstalling. If the connecting rod bolt is longer than 48 mm (1.8 inches) then replace the connecting rod with a new one.

Install the connecting rod bearing caps. Tighten the connecting rod bearing cap bolts to 22-27 Nm (16-19 ft. lbs.), then another 90 +/- 5 degrees.

(Part 3 Of 3):

8. Apply a bead of silicone sealant to the crankshaft rear oil seal retainer as shown.
9. Install the crankshaft rear oil seal retainer. Tighten the crankshaft rear oil seal retainer bolts to 8-10 Nm (71-88 inch lbs.).
10. Apply a small amount of clean engine oil to the lip of the crankshaft rear oil seal.
11. Use Crankshaft Rear Seal Pilot T88P-6701-B2 and Crankshaft Rear Seal Replacer T88P-6701-B1 to install the crankshaft rear oil seal until it is flush with the edge of the crankshaft rear oil seal retainer.

(Part 3 Of 3):

12. Apply a bead of silicone sealant to the oil pump as shown.
13. Install the oil pump. Tighten the oil pump bolts to 19-25 Nm (14-18 ft. lbs.).
14. Install a new water pump housing gasket on the water pump.
15. Install the water pump. Tighten the water pump bolts to 19-25 Nm (14-18 ft. lbs.).
16. Install the timing belt idler. Tighten the timing belt idler bolt to 37-52 Nm (27-38 ft. lbs.).

Fig. 23, Applying Sealant To Stiffener:

17. Apply a bead of silicone sealant around the circumference of the stiffener and the four bolt holes as shown.





18. Install the stiffener. Tighten the stiffener bolts in two steps in the sequence shown, to 19-25 Nm (14-18 ft. lbs.).





19. Tighten the crankshaft rear oil seal retainer-to-stiffener nuts to 8-10 Nm (71-88 inch lbs.).
20. Install the oil pump screen cover and tube and a new oil pump inlet tube gasket. Tighten the oil pump screen cover and tube bolts to 8-10 Nm (71-88 inch lbs.).





21. Apply a continuous bead of silicone sealant to the oil pan as shown.
22. Install the oil pan. Tighten the oil pan bolts to 19-25 Nm (14-18 ft. lbs.).
23. Install a new head gasket.





24. Measure the length of each cylinder head bolt before reinstalling. If the cylinder head bolt length is longer than 105.5 mm (4 inches) then replace the cylinder head bolt with a new one.








Install the cylinder head. Tighten the cylinder head bolts in two steps to 18-22 Nm (13-16 ft. lbs.), in the sequence shown.

25. After initial tightening, apply a paint mark to the cylinder head bolts and turn all bolts 90 +/- 5 degrees in the sequence shown. Turn all the cylinder head bolts another90 +/- 5 degrees in the sequence shown.





26. Install the camshafts. sealant to the shaded areas of the camshaft thrust plate surfaces as shown.

NOTE: Ensure that none of the camshaft lobes are located directly on the hydraulic lash adjusters.





27. Install the camshaft thrust plates and the camshafts bearing caps. Tighten the sixteen camshaft bearing cap bolts and the four camshaft thrust plate bolts in three steps to 4 Nm (35 inch lbs.), to 8 Nm (71 inch lbs.) and to 12-14 Nm (100-1-26 inch lbs.), in the sequence shown.

NOTE: Install the camshaft thrust plates and the camshaft bearing caps in their original positions. Refer to the numbers noted during disassembly.

28. Apply a small amount of clean engine oil to the lip of the new camshaft front seals.





29. Use Cam Seal Replacer T9OP-6256-BH and Cam Seal Protector-AH to install the camshaft front seals.





30. Install the camshaft sprockets on the camshafts as shown.





31. Install the camshaft sprocket bolts. Tighten the camshaft sprocket bolts to 49-61 Nm (36-45 ft. lbs.).

NOTE: Hold the camshaft sprockets with a suitable wrench as shown.

32. Install the CKP sensor and CKP sensor bolt. Tighten the CKP sensor bolt to 8-10 Nm (71-88 lb-in).
33. Install the timing chain guide and crankshaft sprocket.





34. Install the RH engine support insulator mounting bracket. Tighten the three RH engine support insulator mounting bracket bolts to 43-61 Nm (32-45 ft. lbs.).
35. Temporarily install the crankshaft pulley bolt on the crankshaft.
36. Align the timing mark on the crankshaft sprocket with the timing mark on the oil pump.





37. Align the timing marks on the camshaft as shown.





38. Insert Camshaft Pulley Holding Tool T92C-6256-AH.
39. Install the timing belt.
40. Install the timing belt tensioner. Tighten the timing belt tensioner bolt to 37-52 Nm (27-38 ft. lbs.).





41. While turning the timing belt tensioner clockwise with an Allen wrench, install the timing belt tensioner spring.
42. Remove Camshaft Pulley Holding Tool T92C-6256-AH.
43. Rotate the crankshaft clockwise two complete revolutions and check timing mark alignment.
44. Remove the crankshaft pulley bolt.
45. Install the lower engine front cover. Tighten the lower engine front cover bolts to 8-10 Nm (71-88 inch lbs.).
46. Install the upper engine front cover. Tighten the upper engine front cover bolts to 8-10 Nm (71-88 inch lbs.).
47. Install the oil level indicator tube and tighten the oil level indicator tube bolt to 8-10 Nm (71-88 inch lbs.).





48. Install the water pump pulley. Use Water Pump Pulley Tool T92C-6312-AH. Tighten the water pump pulley bolts to 8-10 Nm (71-88 inch lbs.).

NOTE: When installing the water pump pulley ensure that the "F" marks are pointing away from the engine.





49. Apply a coat of silicone sealant to the new valve cover gasket, then install the valve cover gasket on the valve cover.





50. Apply silicone sealant to the cylinder head in the shaded areas shown.





51. Install the valve cover. Tighten the valve cover bolts in two steps to 6-7 Nm (52-69 inch lbs.), in the sequence shown.
52. Position a new water inlet connection gasket and install the water inlet connection with the water bypass hose and the heater hot water tube. Tighten the water inlet connection bolts to 19-25 Nm (14-18 ft. lbs.).
53. Install the engine lifting eyes. Tighten the engine lifting eye bolts to 37-52 Nm (27-38 ft. lbs.).
54. Tighten the water bypass hose bracket bolt to 19-25 Nm (14-18 ft. lbs.).
55. Tighten the heater hot water tube bracket bolt to 19-25 Nm (14-18 ft. lbs.).
56. Position a new water hose connection gasket and install the water hose connection. Tighten the water hose connection bolts to 19-25 Nm (14-18 ft. lbs.).
57. Position a new exhaust manifold gasket and install the exhaust manifold. Tighten the eight exhaust manifold bolts to 16-23 Nm (12-17 ft. lbs.).
58. Replace the two exhaust manifold nuts. Tighten the exhaust manifold nuts to 20-28 Nm (14-21 ft. lbs.).
59. Install the exhaust manifold shield. Tighten the seven exhaust manifold shield bolts to 8-10 Nm (71-88 inch lbs.).
60. Install a new distributor O-ring.





61. Align the alignment marks on the distributor shaft and distributor housing.
62. Apply a small amount of clean engine oil to the new distributor O-ring and install the distributor.
63. Tighten the two distributor bolts to 19-25 Nm (14-18 ft. lbs.).
64. Install a new intake manifold gasket.





65. Install the intake manifold. Tighten the five intake manifold bolts and two nuts to 19-25 Nm (14-18 ft. lbs.) in the sequence shown.
66. Connect the throttle body coolant line.
67. Connect the IAC BPA valve coolant line.
68. Apply silicone sealant to the threads of the oil pressure sensor.





69. Apply Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to the threads of the oil pressure switch.

Install the oil pressure switch. Tighten the oil pressure switch to 12-17 Nm (105-156 inch lbs.).

CAUTION: Do not apply the Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to the first 1.5-2.5 mm (0.06-0.09 inch) of the threads.

70. Install the EGR valve to exhaust manifold tube between the exhaust manifold and the intake manifold. Tighten the EGR valve-to-exhaust manifold tube nut to 32-47 Nm (24-34 ft. lbs.).
71. Install the PCV valve in the valve cover.
72. Install the oil filter. Tighten the oil filter 1 and 1/6 turns after the gasket contacts the mounting surface.
73. Install the spark plugs. Tighten the spark plugs to 15-23 Nm (11-17 ft. lbs.).
74. Connect the distributor to spark plug wires in the order noted during disassembly.