Disassembly and Assembly
NOTE: Before starting disassembly, remove accessories and any emission control equipment which is not directly attached to the engine.DISASSEMBLY
1. Remove flywheel.
2. Remove exhaust manifolds. With LH exhaust manifold removed, note the location of the oil level indicator tube bracket.
3. Remove positive crankcase ventilation valve (PCV~valve).
4. Disconnect ignition wires from the spark plugs.
NOTE: When removing an ignition wire from a spark plug, use Spark Plug Wire Remover T74P-6666-A. Grasp and twist the boot back and forth on the plug insulator to free the boot. Use the tool to pull the boot from the plug. Do not pull on the ignition wire directly or it may become separated from the connector inside the boot.
5. Remove EGR valve (EGR valve) and EGR valve gasket, if so required.
6. Remove the throttle body.
7. Remove crankshaft pulley and the crankshaft damper. Use Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B to remove vibration damper.
8. Remove hold-down clamp and the camshaft position sensor and camshaft position sensor (CMP sensor).
9. Remove valve covers.
10. Before attempting to remove the lower intake manifold, break the seal between the lower intake manifold and the cylinder block. Wedge a large pry bar between the lower intake manifold and the cylinder block. Pry downward on the pry bar using the lug on the water pump as a leverage point.
CAUTION: Use care to prevent damage to machined surfaces or possible engine oil and coolant leakage may occur.
11. Remove rocker arms and push rods.
Note the location of each rocker arm, push rod and rocker arm se. When engine is assembled each component must be installed in its original position.
12. Remove spark plugs.
13. Remove lower intake manifold and intake manifold gasket. Discard intake manifold gasket.
14. Remove cylinder heads. Discard cylinder head retaining bolts.
15. Remove and discard head gaskets.
16. Remove valve tappets.
NOTE: The location of each valve tappet should be identified. When the engine is assembled each valve tappet should be installed in its original position.
If the valve tappets are stuck in the bores due to excessive varnish or gum deposits, it may be necessary to use a magnet or claw-type tool to aid removal. When using a~remover tool rotate the valve tappet back and forth to loosen it from the gum or varnish that may have formed on the valve tappet.
17. Remove oil bypass filter.
18. Remove oil pan and oil pan gasket. Discard oil pan gasket.
19. Remove oil pump.
20. Remove water pump and engine front cover as an assembly. Remove and discard engine front cover gasket.
NOTE: If necessary, the water pump can be removed from the engine front cover. Discard water pump housing gasket after removal.
21. Remove camshaft sprocket retaining bolt.
22. Remove camshaft sprocket, the crankshaft sprocket and the timing chain.
CAUTION: Use care to prevent damage to finished areas on the crankshaft or possible engine damage may occur.
NOTE: If the crankshaft sprocket is difficult to remove, it can be pried off using two large pry bars.
23. Remove camshaft thrust plate bolts and camshaft thrust plate from the end of the camshaft.
24. Remove camshaft. Use care to prevent damage to camshaft bearing surfaces.
25. If necessary, remove camshaft rear bearing cover from the back of the engine.
26. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Rotunda Cylinder Ridge Reamer 014-00292 or equivalent. Before the ridge or deposits are removed, turn the crankshaft until the piston is at the bottom of its stroke. Cover the piston with a clean shop towel to collect the cuttings. After the cutting operation, turn the crankshaft until the piston is at the top of its stroke and remove the shop towel with the cuttings.
CAUTION: Never cut into the ring travel area in excess of 0.794 mm (0.031 inch) or possible damage to engine may occur.
27. Remove connecting rod caps and pistons.
NOTE: The cylinder number is stamped on the top of the piston. Matched letters are stamped on the sides of corresponding connecting rod and cap.
Note the location of each piston, connecting rod bearing and connecting rod cap. When the engine is assembled each component must be installed in its original position.
28. Remove crankshaft main bearing caps and crankshaft.
NOTE: Identify the location of the crankshaft main bearings. When the engine is assembled, each crankshaft main bearing must be installed in its original position.
29. For cleaning purposes, oil gallery and cooling jacket plugs can be removed.
ASSEMBLY
1. If removed, install oil gallery and cooling jacket plugs. Tighten plugs to 20 Nm (15 ft. lbs.). Before installation, coat plug threads with Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-AZ and ESR-M18P7-A.
NOTE: During assembly of the engine, Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5 will be applied to many areas before installation. When the sealant is applied, the component should be installed within 15 minutes. After this time the sealant begins to set-up and its sealing effectiveness can be reduced. Lightly oil all retaining bolt and stud bolt threads before installation except those specifying special sealant.
2. Install crankshaft as follows:
a. Install crankshaft main bearings in the appropriate cylinder block saddle. Note that third bearing from front is the crankshaft thrust main bearing.
b. Lubricate crankshaft main bearings with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Carefully lower the crankshaft into place.
CAUTION: Use care to prevent damage to bearing surfaces or possible engine damage may occur.
c Apply a 6 mm (0.25-inch) dot of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 between rear main bearing cap and cylinder block as shown.
NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
d. Install lower crankshaft main bearings in the main caps. Note that caps are numbered with arrow heads. No. 1 is located at front of engine with arrow head facing front of engine. No.2 is main bearing cap and has two arrow heads pointing to front of engine and so on.
e. Apply clean engine oil XO-1OW30-QSP or -DSP meeting Ford specification ESE-M2C 153-E to main bearing caps. Install bolts finger-tight.
NOTE: Crankshaft main bearing caps are precision fit to surrounding metal parts. A slight tap with a plastic mallet will help to locate cap. Use care to prevent damage.
f. Before tightening main bearing cap retaining bolts/stud bolts, wedge a large pry bar between cylinder block web and crankshaft cheek located in front of the No.3 crankshaft main bearing. Do not jam the pry bar into place. Apply sufficient force only to push crankshaft forward while the main bearing cap bolts are tightened.
g. Tighten main bearing cap retaining bolts/stud bolts to 75-85 Nm (56-62 ft. lbs.) and remove pry bar.
h. Check crankshaft end play.
3. Install crankshaft rear oil seal.
4. Install piston rings on pistons using a ring expander. Make sure piston ring lands are completely clean of carbon deposits before installing rings. Check piston ring end gap in each cylinder prior to piston installation.
5. Install the piston as follows:
a. Install connecting rod bearings in the connecting rods and the connecting rod caps. Make sure bearing locating tang is properly located and connecting rod bearing is completely seated.
b. Lubricate piston rings, cylinder walls, and bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
c. Arrange piston ring gaps alternately around the pistons so no gaps are in line with another.
d. Install a 50 mm (2 inch) piece of 3/8 inch fuel line (or straight ignition wire spark plug boot) on both connecting rod bolts prior to installation to prevent damage to crankshaft rod journals.
e. . Install pistons using Rotunda Piston Ring Compressor 014-00290 or equivalent: The notch in the piston dome and button on connecting rods must face the front of the engine.
f. Rotate crankshaft journal to bottom of its stroke for each piston installation. Using a wooden hammer handle, tap piston into cylinder bore. At the same time, guide connecting rod end into position onto crankshaft journal. Seat connecting rod bearing fully against journal. Remove rubber protection from connecting rod bolts. Aligning both bearing locating tangs on the same side, install connecting rod cap and retaining nuts.
- Alternate evenly between both retaining nuts, tighten to 31-39 Nm (23-28 ft. lbs.).
6. Check connecting rod side clearance.
7. Install camshaft rear bearing cover. Coat the sealing edge of the camshaft rear bearing cover with Perfect Seal Sealing Compound B5A-19554-A or equivalent meeting Ford specification ESR-M 18P2-A before installation. Using a suitable driver, install camshaft rear bearing cover square into bore.
8. If necessary, replace camshaft bearings.
9. Lubricate camshaft lobes, distributor drive gear and bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Carefully slide camshaft through camshaft bearings into cylinder block. Remember to keep camshaft perfectly in line with front camshaft bearing.
10. Install camshaft thrust plate. Tighten retaining bolts to 10 Nm (8 ft. lbs.).
11. Check camshaft end play.
Fig. 8 Timing Chain Alignment:
12. Install timing chain and camshaft sprocket and crankshaft sprocket as an assembly. Lubricate timing chain with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
Rotate crankshaft and camshaft to align sprocket timing marks as shown.
13. Install camshaft sprocket retaining bolt and washer and tighten to 50-70 Nm (37-51 ft. lbs.). Check the drilled oil passages of the bolt to ensure they are not plugged. Clean as required. Do not replace with a standard bolt.
14. Install the water pump/engine front cover as an assembly and a new engine front cover gasket. Tighten water pump retaining bolts.
15. Install oil pump and oil pump intermediate shaft. If installing new oil pump, insert oil pump intermediate shaft into oil pump hex drive hole until oil pump intermediate shaft retaining ring clicks into place. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
16. Locate oil pan gasket to oil pan and secure with Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specifications ESR-M11P7-A and ESE-M2G52-A. Apply a 5 mm (0.187 inch) bead of Silicone Sealer to the engine front cover-to-cylinder block junction, and to the rear main bearing cap-to-cylinder block junction.
NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
17. Install oil pan and tighten retaining bolts to 10-14 Nm (8-10 ft. lbs.). Tighten the four corner fasteners first, then tighten remaining 12. Back off all retaining bolts and then re-tighten to the original value.
18. Lubricate oil bypass filter gasket with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install oil bypass filter.
19. Lubricate valve tappets with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install into their original positions relative to camshaft lobe and push rod.
20. Install new head gaskets onto cylinder block using the cylinder head to block dowel to align the head gasket.
NOTE: Make sure the "UP" designation is facing the cylinder head.
21. Install cylinder heads. Tighten retaining bolts in two steps in the sequence as shown:
- 50 Nm (37 ft. lbs.)
- 92 Nm (68 ft. lbs.)
22. Apply Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to intersection of cylinder block end rails and cylinder heads (four places).
NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
23. Install front and rear intake manifold end seals.
24. Position intake manifold gaskets in place.
25. Carefully lower intake manifold into position to prevent smearing the silicone sealer and causing leak paths.
NOTE: Intake manifold gaskets are marked "to intake manifold" which faces intake manifold sealing surface. Insert locking tabs over head gasket locating tabs as shown.
26. Install retaining bolts and tighten in numerical sequence as shown to the following specifications in two steps:
- 20-30 Nm (15-22 ft. lbs.)
- 26-32 Nm (19-24 ft. lbs.)
NOTE: Retaining bolts require a Torch head socket.
27. Lubricate push rods and rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
CAUTION: Rocker arm seats must be fully seated in cylinder head, and push rods must be seated in rocker arm sockets prior to final tightening.
28. Install push rods in their original positions.
29. Rotate rocker arms onto push rods making sure push rod is seated properly on valve tappet and in rocker arm. Tighten retaining bolt to 7-15 Nm (5-11 ft. lbs.) to seat rocker arm seats into cylinder head.
30. Rotate crankshaft to position valve tappet on the heel of the camshaft lobe (base circle - O lift).
- Tighten retaining bolts of specified rocker arms to 7-15 Nm (5-11 ft. lbs.).
- Final-tighten all rocker arm seat bolts (camshaft may be in any position) to 26-38 Nm (19-28 ft. lbs).
31. Install water hose connection and water hose connection gasket as illustrated if removed. Tighten retaining bolts to 10-14 Nm (8-10 ft. lbs.).
32. Install fuel injection supply manifold and fuel injectors if removed. Apply Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to fuel injector bores in lower intake manifold and fuel injection supply manifold prior to fuel injector installation.
- Install fuel injection supply manifold retaining bolts and tighten to 8-12 Nm (71-106 inch lbs.).
33. Install valve covers. Install bolts and stud bolts. Tighten to 10-14 Nm (8-10 ft. lbs.).
34. Install oil filler cap.
35. Install fuel charging wiring to the appropriate locations. Locate and install harness stainers to the valve cover retaining stud bolts.
36. Install throttle body and new intake manifold upper gasket.
37. Coat entire camshaft position sensor housing gear with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install camshaft position sensor housing and camshaft position sensor.
CAUTION: If a new camshaft and/or camshaft position sensor housing is installed, ALWAYS add the rest of the Engine Assembly Lubricant D9AZ-19579-D or equivalent (pint) meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the hole onto the camshaft drive gear. Run engine at idle for five minutes prior to driving vehicle.
38. Install exhaust manifolds. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).
39. Install oil level dipstick and oil level indicator tube. Apply Perfect Seal Sealing Compound B5A-19554-A or F2AZ-19554-AA or equivalent meeting Ford specifications ESR-M18P2-A and ESE-M4G116-A prior to installation. Tighten retaining nut to 15-20 Nm (11-14 ft. lbs.).
40. Install spark plugs.
41. Connect ignition wires to spark plugs. Locate with ignition wire separators to appropriate valve cover retaining stud bolts.
42. Install crankshaft damper using Vibration Damper and Seal Replacer T82L-6316-A. Tighten retaining bolt to 125-165 Nm (93-121 ft. lbs.).
43. Install oil pan. Tighten retaining bolts to 73-87 Nm (54-64 ft. lbs.) in the standard cross-tightening sequence.
NOTE: Apply Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G 195-A to keyway slot in damper and lubricate outside of damper hub with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification: ESE-M2C153-A prior to installation.