Assembly
Part 1 Of 2:
Part 2 Of 2:
1. If removed, install oil gallery and cooling jacket plugs. Tighten plugs to specification.
- Before installation, coat plug threads with Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2.
- To provide clearance for camshaft sprocket, oil gallery plugs on front of engine must be threaded below machined surface.
NOTE:
- During engine assembly, silicone sealer will be applied to many components before installation. When the sealant is applied, the component should be installed within 15 minutes. After this time, the sealant begins to set-up and its sealing effectiveness can be reduced.
- Lightly oil all retaining bolt and stud threads before installation except those specifying special sealant.
2. Install crankshaft as follows:
a. Install crankshaft main bearings in cylinder blocks. Note that third crankshaft main bearing from front is the crankshaft thrust main bearing (6337).
b. Lubricate crankshaft main bearings with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and carefully lower crankshaft into place. Use care to prevent damage to bearing surfaces.
c. Apply a 3 mm (0.125 inch) bead of Silicone Rubber D6AZ-19562-BA or AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to cylinder block rear main bearing cap parting line.
NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residue that may interfere with the sealers ability to adhere.
d. Install crankshaft main bearings in main bearing caps and install caps. Note that caps are numbered with triangles. Cap No.1 is located at the front of engine with triangle facing front of engine.
e. Install main bearing cap retaining bolts.
f. Before tightening main bearing cap retaining bolts, wedge a large prybar between cylinder block web and crankshaft cheek located in front of No.3 crankshaft main bearing.
CAUTION: Do not jam prybar into place. Tap into position only enough to hold crankshaft forward while cap bolts are tightened.
g. Tighten main bearing cap retaining bolts in two steps: tighten to 50 Nm (37 ft. lbs.), tighten an additional 115-125 degrees.
3. Check crankshaft end play.
4. Install pistons as follows:
a. Install connecting rod bearings in connecting rods (6200) and connecting rod caps.
b. Install pistons using Piston Ring Compressor D81L-6002-C or equivalent. The notch in piston dome must face the front of engine.
NOTE:
- Lubricate piston and cylinder walls with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installation.
- Scratching of crankshaft journal can be prevented by covering connecting rod bolts with ignition wire spark plug boots or flexible hose.
c. Install connecting rod caps and retaining bolts as follows:
- tighten to 20-25 Nm (15-18 ft. lbs.).
- tighten retaining nuts to 40-45 Nm (30-33 ft. lbs.).
- rotate nuts an additional 90-120 degrees.
5. Check connecting rod side clearance.
6. Install camshaft rear bearing cover using a suitable driver.
NOTE: Coat sealing edge of camshaft rear bearing cover with Perfect-Seal Sealing Compound B5A-19554-A or equivalent meeting Ford specification ESE-M4G115-A before installation.
7. Coat camshaft lobes and camshaft bearings (6261) with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
8. Install camshaft, camshaft sprocket spacer and key.
9. Install camshaft thrust plate and tighten retaining bolts to 8-14 Nm (71-123 inch lbs.).
10. With the timing chain vibration damper in the compressed position, install the timing chain vibration damper and retaining bolts. Tighten retaining bolts to 8-14 Nm (71-123 inch lbs.).
11. Lubricate timing chain with clean engine oil meeting Ford specification WSS-M2C153-F.
12. Rotate crankshaft, as necessary, to position crankshaft sprocket keyway in 12 o'clock position.
Fig. 9 Timing Chain Alignment:
13. Install camshaft sprocket, crankshaft sprocket and timing chain at the same time.
- Make sure crankshaft keyway, camshaft sprocket timing mark and crankshaft sprocket timing mark are properly aligned after installation.
14. Install distributor drive gear.
15. Install camshaft sprocket retaining bolt and washer. Tighten bolt to 40-50 Nm (30-36 ft. lbs.).
16. Remove timing chain vibration damper retaining pin.
17. If water pump was removed from engine front cover during engine disassembly, position a new water pump housing gasket (8507) on engine front cover and install water pump.
- Tighten water pump retaining bolts to 20-30 Nm (15-22 ft. lbs.). Tighten water pump retaining nuts to 8-12 Nm (71-106 inch lbs.).
18. Position a new engine front cover gasket on engine. Install engine front cover. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).
19. Install oil pump screen cover and tube using a new oil pump inlet tube gasket.
- Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.) and support bracket retaining nut to 40-55 Nm (30-40 ft. lbs.).
20. Install oil pan as follows:
a. Using a small-blade screwdriver, remove any sealer which may have been squeezed into seal groove when rear main bearing cap was installed. Place a 6.35 mm (0.25 inch) bead of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A into seal groove where main bearing cap meets cylinder blocks.
NOTE: Prior to applying sealer, clean oil pan and cylinder block sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RH or equivalent meeting Ford specification WSE-M5B392-A, to remove all residue that may interfere with the sealers ability to adhere.
b. Apply a 3 mm (0.125 inch) bead of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to seams where engine front cover mates with cylinder blocks and to each end of oil pan end seal.
c. Apply silicone rubber in a zig-zag pattern on cylinder blocks.
d. Install oil pan. Tighten in sequence in two steps:
- 4-5 Nm (36-44 inch lbs.)
- 9-12 Nm (80-106 inch lbs.).
21. Lubricate oil bypass filter gasket with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
- Thread oil bypass filter onto adapter until gasket contacts cylinder blocks and then advance oil bypass filter an additional one-half turn.
22. Lubricate valve tappets with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install.
23. Install six valve tappet guide plates (6K512) and two tappet guide plates and retainers. Tighten tappet guide plate and retainer retaining bolts to 10-14 Nm (89-123 inch lbs.).
24. Install new head gaskets using cylinder head to block dowels (6A008) to align head gasket.
NOTE: RH and LH head gaskets are not interchangeable.
25. Install cylinder head.
26. Install push rods, rocker arms, rocker arm seats and retaining bolts. Lubricate push rod ends and rocker arm seats with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installation.
- For each valve, rotate crankshaft until valve tappet rests on heel (base circle) of camshaft lobe. Tighten rocker arm seat retaining bolt to 5 Nm (44 inch lbs.) MAX. Final-tighten rocker arm seat retaining bolts to 30-40 Nm (22-30 ft. lbs.). For final-tightening, camshaft may be in any position.
27. Install lower intake manifold.
28. Install spark plugs. Tighten to 9-20 Nm (80-177 inch lbs.).
29. Install valve covers as follows:
a. Install a new valve cover gasket (6584) onto cylinder head.
b. Install valve cover and retaining bolts. Note location of stud/bolts.
c. Tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).
NOTE: Using solvent, clean valve cover and cylinder head sealing surfaces to remove all gasket material and dirt.
30. Install camshaft position sensor, housing and hold-down clamp.
31. Install crankshaft pulley and vibration damper using Damper/Front Cover Seal Replacer T82L-6316-A and Front Cover Seal Replacer T70P-6B070-A. Tighten retaining bolt to 140-180 Nm (103-132 ft. lbs.).
32. Install upper intake manifold.
33. Install fuel injectors and fuel injection supply manifold. Tighten retaining bolts for fuel injection supply manifold bracket to 8-11 Nm (71-97 inch lbs.).
34. Connect the front evaporative emissions tube and install the following positive crankcase ventilation system components:
- Front and rear crankcase ventilation tube.
- Positive crankcase ventilation valve.
35. Install upper intake manifold. Tighten bolts and studs in numerical sequence in three steps:
a. 10 Nm (8 ft. lbs.).
b. 20 Nm (15 ft. lbs.).
c. 32 Nm (24 ft. lbs.).
NOTE: Apply a light coat of Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to retaining bolts and stud bolt threads prior to installation.
36. Install EGR valve. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).
37. Connect ignition wires to spark plugs.
38. Inspect heater water outlet tube O-ring (replace as necessary) and install heater water outlet tube. Install and tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).
39. Install water bypass tube to intake manifold. Tighten hose clamp securely.
40. Install exhaust manifolds. Note location of oil level indicator tube support bracket. Tighten exhaust manifold retaining bolts in sequence to 30-36 Nm (23-36 ft. lbs.).
41. Install engine rear plate and flywheel.
- Tighten flywheel retaining bolts to 73-87 Nm (54-64 ft. lbs.) in a standard cross-tightening sequence.
NOTE: Apply a thin coat of Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to flywheel retaining bolt threads before installation.