Part 1 of 2

1. Lubricate and install the crankshaft main bearings into the cylinder block. Install the crankshaft main bearings into the main bearing caps.
- Use clean engine oil meeting Ford specification WSS-M2C153-G.

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.





2. Install crankshaft into the cylinder block.





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

CAUTION: Make sure coated side of thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.





4. Loosely install the main caps and bolts.





5. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.
6. Push the No. 5 main cap rearward and tighten.





7. Tighten the bolts 1 through 20 in the sequence shown.

NOTE: Make sure to tighten the bolts in four steps.





8. Tighten the bolts 1 thru 10 in the sequence shown.





9. Tighten the bolts 11 thru 20 in the sequence shown.





10. Tighten the bolts 1 thru 20 in the sequence shown.





11. Turn the ten jack screws until fully seated in the main bearing cap.





12. Install and tighten the jack screws in the sequence shown.





13. Install and tighten the cross-mounted bolts.
14. Check the crankshaft end play.
15. Rotate the crankshaft to make sure it turns freely.





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

Use the Connecting Rod Guide and the Piston Ring Compressor to install the piston and connecting rod assembly.
- Lubricate the piston and ring with engine oil.
- Lubricate the rod bearings with engine oil.
- Check ring orientation.

NOTE: Make sure the piston arrow is facing forward.






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

Remove the Connecting Rod Guide when the connecting rod is seated on the crankshaft journal.

NOTE: Make sure the crankshaft is T.D.C.





18. Install No. 1 and 6 pistons, rod and caps. Install bolts.





19. Tighten the bolts in the sequence shown.
20. To install No. 3 and 5, 4 and 7, 2 and 8, turn the crankshaft 90 degrees and repeat Steps 18 and 19.
21. Measure the connecting rod clearance.





22. Apply silicone around the rear oil seal retainer sealing surface.
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.





23. Install the crankshaft rear oil seal and retainer and loosely install the bolts.





24. Tighten the bolts in the sequence shown.





25. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal.





26. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the crankshaft oil slinger.





27. Install and tighten the oil pump screen and cover spacer.





28. Position the oil pump and install the bolts in the sequence shown.





29. Install oil pump screen cover and tube and install the bolts for the oil pump screen and cover.

NOTE: Check O-ring on the oil pump pick up tube for tears or damage.





30. Install the oil filter adapter and the oil filter adapter gasket and install the bolts for the oil filter adapter in the sequence shown.





31. Install the oil bypass filter.





32. Apply Silicone and Gasket Sealant F6AZ-19562-AA meeting Ford specification WSE-M4G323-A6 to the front cover to cylinder block parting lines. Install the oil pan and the oil pan gasket. Loosely install the 12 bolts for the oil pan.





33. Tighten the bolts for the oil pan in the sequence shown.





34. Install and tighten the Knock Sensor (KS).





35. Install the head gasket.





36. Position the crankshaft and the camshaft as shown.

CAUTION: Make sure the crankshaft and the camshaft are positioned properly to prevent piston crown and valve damage.





37. Install the LH cylinder head and the RH cylinder head. Loosely install new bolts.
38. Tighten the RH bolts in six stages in the sequence shown.
- Stage 1: Tighten to 37-43 Nm (28-31 lb-ft).
- Stage 2: Tighten an additional 85-95 degrees.
- Stage 3: Loosen the bolts a minimum of one full turn.
- Stage 4: Tighten to 37-43 Nm (28-31 lb-ft).
- Stage 5: Tighten an additional 85-95 degrees.
- Stage 6: Tighten an additional 85-95 degrees.





39. Tighten the LH bolts in six stages in the sequence shown.
- Stage 1: Tighten to 37-43 Nm (28-31 lb-ft).
- Stage 2: Tighten an additional 85-95 degrees.
- Stage 3: Loosen the bolts a minimum of one full turn.
- Stage 4: Tighten to 37-43 Nm (28-31 lb-ft).
- Stage 5: Tighten an additional 85-95 degrees.
- Stage 6: Tighten an additional 85-95 degrees.





40. Install the water bypass tube.
- Install the water bypass tube.
- Install the bolts.





41. Install the RH and the LH timing chain guide.





42. Install the timing chain and crankshaft sprockets and make sure that the RH timing chain gear is in front of the LH timing chain gear with the hubs facing each other.

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





43. Check that the copper links on the timing chain is lined up with the corresponding dots on the timing chain gears.





44. Check that the keyway on the camshafts sprocket are 90 degrees from the camshaft cover surface.





45. Install the RH and the LH timing chain tensioner arm.





46. Install the RH and the LH timing chain tensioner.
47. Remove pins from tensioner.





48. Tighten the camshaft sprocket bolts.
49. Apply silicone along the head-to-block surface and to oil pan (6 places).
- Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.





50. Install the crankshaft position sensor (cap) pulse wheel with hub facing crankshaft sprockets.





51. Install the engine front cover on the dowel pins on the front of the cylinder block.