Assembly

1. Install the upper crankshaft main bearings.





2. Note: Lubricate the crankshaft journals and the crankshaft main bearings with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the crankshaft.





3. Note: Lubricate the inner and outer sealing surfaces of the crankshaft rear oil seal with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the crankshaft rear oil seal.





4. Apply two dots of Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5 between the rear bearing cap and the cylinder block.





5. Install the lower crankshaft main bearings.





6. Install the main bearing caps.





7. Wedge a large screwdriver at the location shown to hold the crankshaft forward until all the bolts are tightened.





8. Install the bolts.
- Tighten the bolts in pairs.





9. If removed, install the camshaft bearings.
- Use the Camshaft Bearing Service Set.





10. Note: Lubricate the camshaft and the camshaft bearings with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the camshaft.





11. Install the camshaft retainer.
12. Inspect the camshaft end play.





13. Align timing marks.





14. Install the timing chain/belt, the camshaft sprocket and the crankshaft sprocket as an assembly.





15. Install the bolt.





16. Note: Lubricate the piston and connecting rod assemblies with clean Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the piston and connecting rod assemblies.
- Use a piston ring compressor.

17. Note: Lubricate the connecting rod bearings with Super Premium SAE SW-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the connecting rod bearings.





18. Install the connecting rod caps and nuts.
- Tighten the nuts in pairs.





19. Install the oil pump.





20. Note: Lubricate the valve tappets with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the valve tappets.





21. Install the valve tappet guide plates.





22. Install the valve tappet guide plate retainer.





23. Install the head gaskets.





24. Install the cylinder heads.





25. Install the bolts. Tighten the bolts in the sequence shown in four steps.
1 Tighten the bolts to 80 Nm (59 ft. lbs.).
2 Loosen the bolts one full turn.
3 Tighten to 45 - 55 Nm (34 - 40 ft. lbs.).
4 Tighten to 85 - 99 Nm (63 - 73 ft. lbs.).





26. Install the oil bypass filter.





27. Install the oil level indicator tube.





28. Install the EGR valve to exhaust manifold tube.





29. Install a new engine front cover gasket and the engine front cover.





30. Apply Pipe Sealant with Teflon D8AZ-19554-A meeting Ford specifications ESR-M18P7-A on the bolts to be installed in the locations shown.





31. Install the bolts.
- Tighten the bolts in the sequence shown.





32. Install the Crankshaft Position (CKP) sensor.





33. Apply four beads of Gasket Maker F8AZ-1913508-AB or equivalent meeting Ford specification WSK-M2G348-A5 as shown.





34. Install the oil pan gasket.





35. Install the oil pan and hand-start the bolts.





36. Position the oil pan and install the bolts.
Tighten the bolts in four stages:
- Stage 1: Tighten the four comer bolts to 12 Nm (9 ft. lbs.).
- Stage 2: Tighten the remaining bolts to 12 Nm (9 ft. lbs.).
- Stage 3: Loosen all the bolts one turn.
- Stage 4: Starting from the rear of the oil pan tighten all the bolts to 12 Nm (9 ft. lbs.).
37. Install the camshaft synchronizer.





38. Apply four beads of Silicone Gasket and Sealant.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





39. Install the intake manifold gaskets and end seats.
- Position the end seals.
- Position the intake manifold gaskets.





40. Install the lower intake manifold.
- Tighten the bolts in the sequence shown.





41. Install the push rods and the rocker arms.
- Install the push rods.
- Install the rocker arms.
- Tighten the rocker arm bolts.





42. Apply a bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to the four intake-to-cylinder head seams.





43. If removed, install the valve cover gaskets.





44. Install the valve covers.
- Tighten the bolts in the sequence shown.





45. Position the engine control sensor wiring and connect:
- the camshaft synchronizer.
- the fuel injectors.
- the water temperature indicator sender unit.
- the engine control sensor wiring.





46. Install the intake manifold upper gasket.
47. Install the Positive Crankcase Ventilation (PCV) valve.





48. Install the upper intake manifold.
- Install the upper bolts.
- Tighten in the sequence shown.





49. Connect the engine control sensor wiring to:
- the Idle Air Control (IAC) valve.
- the Throttle Position (TP) sensor.
- the EGR transducer.





50. Using the Crankshaft Damper/Seal Installer, install the crankshaft damper.





51. Install the bolt.





52. Install the crankshaft vibration damper and the bolts.





53. Install the water pump pulley and the bolts.





54. Install the generator mounting bracket and the bolts.





55. Install the nuts.





56. Connect the engine control sensor wiring to:
- the ignition coil.
- the radio ignition interference capacitor.
- the EGR solenoid.
- the vacuum line from the EGR solenoid.





57. Connect the vacuum line.
58. Connect the spark plug wires.