Steps 1 - 47

1. 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.

Lubricate and install the crankshaft main bearings into the cylinder block. Install the crankshaft main bearings into the main bearing caps.
^ Use clean Motorcraft Super Premium SAE 5W-3O Motor Oil XO-5W3O-QSP or equivalent meeting Ford specification WSS-M2C153-G.





2. Install crankshaft into the cylinder block.





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

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





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

Tighten the bolts 1 through 20 in the sequence shown.





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





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





1O. Tighten the bolts in the sequence shown.





11. Install and tighten the cross-mounted bolts to 4O Nm and tighten an additional 9O°.
12. Check the crankshaft end play.
13. Rotate the crankshaft to make sure it turns freely.





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

NOTE: Make sure the piston arrow is facing forward.

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.





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

NOTE: Make sure the crankshaft is TDC.

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





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





17. NOTE: Rod bearing cap bolts are torque to yield and must be replaced each time they are serviced.

Tighten the bolts in the sequence shown.
18. To install No. 3 and 5, 4 and 7, 2 and 8, turn the crankshaft 9O° and repeat Steps 18 and 19.
19. Measure the connecting rod clearance.





2O. Apply silicone around the rear oil seal retainer sealing surface.
^ Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





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





22. Tighten the bolts in the sequence shown.





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





24. With the Rear Crankshaft Sea] Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the crankshaft rear oil slinger.





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





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





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

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





28. Install the oil filter adapter and new O-rings and install the bolts in the sequence shown.





29. Lubricate the threads and gasket with oil and install the oil bypass filter.





3O. Install the knock sensors and tighten the bolts.





31. Install the cylinder head gaskets.





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

Position the crankshaft and the camshafts as shown.





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





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





36. Install the water bypass tube.
^ Install the water bypass tube.
^ Install the bolts.





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





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

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.





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





4O. Check that the keyway on the camshaft sprockets are 9O° from the camshaft cover surface.





41. Install the RH and the LH timing chain tensioner arms.





42. Install the RH and the LH timing chain tensioners.





43. Remove pins from tensioners.
44. Tighten the camshaft sprocket bolts.





45. Install the crankshaft position sensor pulse wheel with hub facing crankshaft sprockets.





46. Apply silicone along the head-to-block surface and to oil pan (6 places).
^ Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





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