Part 1 of 2

Special Tools:

NOTE: Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

1. Lubricate and install the crankshaft main bearings into the cylinder block. Install the crankshaft main bearings into the crankshaft main bearing caps.
- Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

2. NOTE: Do not install the upper thrust bearings until the crankshaft is installed. Refer to Step 3.

Install the crankshaft onto the upper main bearings.

3. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).

Push the crankshaft rearward and install the crankshaft upper washer at the back of the No. 5 main boss.

4. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).

Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.

5. 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 lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.

6. Install the crankshaft lower main bearings 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.

7. Install the dowel pins so the flat sides face the crankshaft.

8. Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 37-43 Nm (27-32 ft. lbs.).
- Stage 2: Tighten an additional 85-95°.

9. Install the side bolts and tighten in two stages, in the sequence shown.
- Stage 1: Tighten to 27-33 Nm (20-24 ft. lbs.).
- Stage 2: Tighten an additional 85-95°.

10. Check the crankshaft end play.

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

NOTE: Make sure the crankshaft is facing forward.

NOTE: Lubricate the piston rings, cylinder walls and connecting rod bearings with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Using the special tool, push the pistons through the top of the cylinder block.

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

NOTE: Make sure the crankshaft is at TDC.

Using the special tool, install the connecting rod assemblies.

13. NOTE: These bolts are torque-to-yield. Install new bolts each time they are serviced.

Install the connecting rod bearing caps and bolts and tighten in three stages.
- Stage 1: tighten to 25 Nm (18 ft. lbs.).
- Stage 2: tighten to 40 Nm (30 ft. lbs.).
- Stage 3: tighten an additional 90°.

14. Check the connecting rod bearing clearance.

15. Install the oil pump and a new gasket. Tighten the bolts in the sequence shown.

16. NOTE: Install a new O-ring if necessary.

Install the oil pump screen cover and tube.

17. Install the cylinder head gaskets.

18. NOTE: The LH is shown the RH is similar.

Tighten the bolts in six stages in the sequence shown.
- Stage 1: tighten to 40 Nm (30 ft. lbs.).
- Stage 2: tighten an additional 90°.
- Stage 3: loosen the bolts a minimum of one full turn.
- Stage 4: tighten to 40 Nm (30 ft. lbs.).
- Stage 5: tighten an additional 90°.
- Stage 6: tighten an additional 90°.

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

CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Compress the tensioner plunger, using the edge of a soft-jawed vise.

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

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

22. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
- Remove the tensioner from the vise.

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

24. Install the timing chain guides.

25. Remove the special tool.

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

27. Install the special tool.

28. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.

CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston or valve damage will occur.

Using the special tool, position the crankshaft.

29. Remove the special tool.

30. Position the inner crankshaft sprocket with the long hub facing outward.

31. Install the LH timing chain onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.

32. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain the timing mark alignment.

Position the timing chain on the camshaft sprocket with the two copper links and the camshaft sprocket timing mark aligned.

33. CAUTION: The camshafts will anode if they are not secure. Be sure that the special tools are locked in position.

NOTE: Be sure the copper links and the sprocket marks are aligned.

NOTE: If necessary adjust the camshaft sprocket to obtain timing mark alignment.

Position the outer crankshaft sprocket and the RH timing chain with the long hub of the sprocket facing inward.

34. Verify the camshaft sprocket-to-copper link alignment.

35. NOTE: The LH tensioner is shown, the RH is similar.

Install the tensioner arms and the tensioners.