Assembly

1. Install the upper crankshaft main bearings into the cylinder block.

CAUTION: Use care not to damage the bearing journals while installing the crankshaft.

2. Install the crankshaft into the cylinder block.
3. Install the lower crankshaft main bearings and the crankshaft main bearing caps.
4. Measure the crankshaft main bearing-to-crankshaft journal clearance with Plastigage(R) D81L-6002-B or equivalent.





5. Tighten the crankshaft main bearing cap bolts to 54-59 Nm (40-43 ft. lbs.) in the order shown.

NOTE: The end play is adjustable through the use of variable thickness crankshaft thrust bearings, located at the number four upper main journal location.

6. Measure the crankshaft end play.
7. Properly space the piston ring gap.
8. Dip the piston in clean engine oil and install Piston Ring Compressor D81L-6002-C.
9. Slip two pieces of snug fitting rubber hose over the connecting rod bolts to prevent bolt-to-crankshaft journal contact during installation.

NOTE: Cylinder numbering starts at the front of the engine.

Fig. 15 Piston & Rod Assembly:

10. Start the connecting rod and piston assembly into the cylinder bore, keeping the F mark on the piston toward the front of the engine. Be sure the connecting rod number and cylinder bore number match.





11. Use a hammer handle or a piece of wood to tap the connecting rod and piston assembly into the cylinder bore. Guide the connecting rod bolts over the crankshaft journal.
12. Insert the connecting rod bearing into the connecting rod cap.
13. Measure the connecting rod bearing-to-crankshaft journal clearance with Plastigage(R) D81L-6002-B or equivalent.

CAUTION: Ensure that the number on the connecting rod (6200) and the connecting rod cap are on the same side and that they match.

14. Install the connecting rod cap.
15. Install the connecting rod nuts. Tighten the connecting rod nuts to 15-17 Nm (11-13 ft. lbs.).
a. Tighten the connecting rod nuts a second time to 29-34 Nm (22-25 ft. lbs.).
b. Check the connecting rod side clearance. The clearance is 0.110-0.262 mm (0.0043-0.0103 inch) with a limit of 0.30 mm (0.012 inch).
17. Repeat steps 7-15 for each of the connecting rod and piston assemblies.
18. Apply Silicone gasket and sealant F6AZ-19562-AA or equivalent to the oil pump to cylinder block gasket (6659) and install the oil pump to cylinder block gasket on the oil pump.
19. Install the oil pump, oil pump screen cover and tube, and oil level indicator tube assembly and gasket.
20. Install the six oil pump bolts. Tighten the oil pump bolts to 19-25 Nm (14-19 ft. lbs.). Install the crankshaft position sensor (CKP). Tighten the CKP sensor bracket bolt to 3 Nm (25 inch lbs.).

Fig. 19 Applying Sealant To Cylinder Block:

21. Apply oil resistant sealer across the joint line of the cylinder block and the oil pump and crankshaft rear oil seal retainer.
22. Install the oil pan and oil pan gasket.
23. Install the oil pan bolts and nuts. Tighten the oil pan bolts and nuts to 8-9 Nm (69-78 inch lbs.).
24. Install the engine support insulator mounting bracket. Install the three engine support insulator mounting bracket bolts. Tighten the three engine support insulator mounting bracket bolts to 39-54 Nm (29-40 ft. lbs.).
25. Install the oil pressure sensor.

NOTE: Ensure the cylinder head and cylinder block gasket surfaces are clean before installing the head gasket.

26. Clean the cylinder head and cylinder block gasket surfaces.





27. Install a new head gasket.

Fig. 3 Cylinder Head Bolt Tightening Sequence:

28. Install the cylinder head and cylinder head bolts. Tighten the cylinder head bolts in the order shown, to 50-60 Nm (35-40 ft. lbs.). Repeat the tightening sequence and tighten the cylinder head bolts to 75-81 Nm (56-60 ft. lbs.).
29. Install the exhaust manifold, the four exhaust manifold bolts and three exhaust manifold nuts. Tighten the exhaust manifold bolts and nuts to 16-23 Nm (12-17 ft. lbs.).
30. Position the exhaust manifold shield and install the exhaust manifold shield bolts. Tighten the exhaust manifold shield bolts to 16-23 Nm (12-17 ft. lbs.).
31. Clean all traces of intake manifold gasket material from the intake manifold and the cylinder head.
32. Position the intake manifold and the intake manifold gasket on the cylinder head.
33. Install the intake manifold bolts and nuts. Tighten the intake manifold bolts and nuts to 19-26 Nm (14-20 ft. lbs.).
34. Install the intake manifold support and the intake manifold support bolts.
35. Tighten the intake manifold support bolts to 31-46 Nm (22-34 ft. lbs.).





36. Align the crankshaft sprocket and crankshaft key and install the crankshaft sprocket.





37. Clean the valve cover and cylinder head sealing surfaces. Apply Threadloc and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5 to the valve cover sealing surface and install a new valve cover gasket as shown.
38. Install the valve cover.
39. Install the six valve cover bolts. Tighten the six valve cover bolts to 5-9 Nm (44-80 inch lbs.).





40. Clean the gasket surfaces of the water pump and the cylinder block. Coat a new water pump housing gasket with Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specifications WSE-M4G323-A6.
41. Position the water pump inlet connector, water pump and water pump housing gasket on the cylinder block.
42. Install the four water pump bolts. Tighten the four water pump bolts to 19-26 Nm (14-19 ft. lbs.).

Fig. 12 Valve Timing Mark Alignment:

43. Align the camshaft sprocket and crankshaft sprocket with the timing marks on the cylinder head and the oil pump housing.
44. Install the timing belt. Ensure the direction mark faces the same way as noted in removal.

Fig. 10 Timing Belt Tensioner Assembly:

45. Install the timing belt tensioner spring and spring cover on the timing belt tensioner (6K254).
46. Position the timing belt tensioner and timing belt tensioner spring assembly on the engine and install the timing belt tensioner bolt. Do not tighten the timing belt tensioner bolt.
47. Install the timing belt tensioner spring on the anchor.
48. Rotate the crankshaft two turns clockwise and align the timing marks. Ensure all marks are still correctly aligned.
49. Tighten the timing belt tensioner bolt to 19-26 Nm (14-19 ft. lbs.).
50. Install the lower engine front cover and two lower engine front cover bolts. Tighten the lower engine front cover bolts to 8-11 Nm (71-97 inch lbs.).
51. Install the upper engine front cover and four upper engine front cover bolts. Tighten the upper engine front cover bolts to 8-11 Nm (71-97 inch lbs.).

NOTE: Before installing the crankshaft pulley bolt, coat the crankshaft pulley bolt threads with Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1.

52. Install the crankshaft pulley hub, and crankshaft pulley bolt. Tighten the crankshaft pulley bolt to 108-118 Nm (80-85 ft. lbs.).
53. Install the crankshaft pulley retaining washer and the four crankshaft pulley retaining washer bolts. Tighten the crankshaft pulley retaining washer bolts to 12-17 Nm (109-152 inch lbs.).
54. Install the water pump pulley.
55. Use a Strap Wrench D85L-6COO-A or equivalent to install the three water pump pulley bolts. Tighten the three water pump pulley bolts to 49-61 Nm (36-45 ft. lbs.).
56. Install the generator.
57. Install the adjustment bolt and generator bolt.
58. Lubricate the oil filter gasket and install by hand. After the oil filter gasket contacts the cylinder block surface tighten the oil filter one-half turn.
59. Install the engine in the vehicle.