Removal and Installation
REMOVAL1. Remove engine from vehicle.
2. Mount engine in a suitable work stand. Drain crankcase and cylinder block cooling jackets.
3. Disconnect ignition wire from the spark plugs.
4. Remove spark plugs.
5. Remove oil pan and oil pump screen cover and tube.
6. Remove cylinder heads to eliminate block distortion.
7. Remove crankshaft pulleys.
8. Remove engine front cover and water pump as an assembly.
9. Remove camshaft synchronizer.
10. Remove crankshaft sprocket, camshaft sprocket and timing chain.
11. Remove flywheel and engine rear plate.
12. Remove connecting rod caps. Turn crankshaft as necessary to position connecting rod in the low point of travel before removing connecting rod cap.
Push piston up into cylinder block bore after removing connecting rod cap. Make sure crankshaft journals are not damaged.
Each connecting rod cap should be identified so it can be installed in its original position during assembly.
13. Remove crankshaft main bearing caps.
14. Carefully lift crankshaft out of cylinder block to prevent damage to bearing surfaces.
NOTE: Handle crankshaft with care to prevent possible damage to finished bearing surfaces.
15. Remove crankshaft rear oil seal and discard.
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16. 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.
INSTALLATION
1. Make sure all bearing surfaces and crankshaft main bearings are clean.
CAUTION: Contaminants on a bearing surface will cause damage to the crankshaft journals.
NOTE: Lightly oil all bolts and stud threads before installation with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
2. If crankshaft main bearing journals have been refinished to definite undersize:
- remove crankshaft main bearings from cylinder block and main bearing caps.
Install new crankshaft main bearings. Make sure tabs on crankshaft main bearings engage slots in the main cap and cylinder block.
3. Make sure crankshaft rear oil seal groove in cylinder block is clean.
4. Carefully lower crankshaft into position in cylinder block. Be careful not to damage crankshaft thrust main bearing.
5. Make sure crankshaft rear oil seal groove in rear main bearing cap is clean and oil drain hole is not blocked.
6. Apply beads of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-AG to rear main bearing cap-to-cylinder block parting line.
NOTE:
- Prior to applying sealer, 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.
- When using silicone sealer, assembly must occur within 7 minutes after sealer application. After this time, the sealer may start to set-up and its sealing effectiveness may be reduced.
7. Lubricate bearing surfaces with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Install main bearing caps and retaining bolts.
8. Tighten main bearing cap retaining bolts as follows:
a. Wedge a prybar between cylinder block web and crankshaft cheek in front of the No. 3 crankshaft main bearing.
Do not jam the prybar into position. Carefully tap on the prybar until it holds crankshaft toward front of engine.
b. Tighten main bearing cap retaining bolts in two steps in sequence. Tighten to 50 Nm (37 ft. lbs.). Rotate an additional 115-125 degrees.
c. Remove prybar.
9. Check crankshaft 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 from connecting rods and connecting rod caps.
Install new connecting rod bearings. Make sure tabs on connecting rod bearings securely engage the slots in connecting rod and cap.
12. Rotate cylinder block 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.
13. Check connecting rod clearance.
As each clearance check is completed, lubricate bearing surfaces with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G before installing connecting rod cap.
Tighten retaining bolts in three steps.
a. Tighten to 20-25 Nm (15-18 ft. lbs.).
b. Tighten to 40-45 Nm (30-33 ft. lbs.).
c. Rotate an additional 90-120 degrees.
14. Install timing chain and engine front cover with water pump.
15. Install Camshaft Position sensor (CMP sensor).
16. Install oil pan.
17. Install engine rear plate and flywheel.
18. Install cylinder heads.
19. Install spark plugs.
20. Connect ignition wires to spark plugs.
21. Install engine in the vehicle.