Part 1

Engine











Special Tool(s)





Material

NOTE: During engine assembly it may become necessary to check bearing clearances, end play, etc.

NOTE: For additional information, refer to the exploded views under Description and Operation.





1. Read the first character code information on the cylinder block face (1) and record the information.





2. Read the first character on the No. 7 crankshaft counterweight and note it.





3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings chart determine the required bearing grade for each main bearing.
^ Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
^ Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade fro the number one crankshaft main bearing.
^ As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is a "2."
^ Repeat this process for the remaining four main bearings.





4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings chart to determine the required bearing grade for each main nearing.

5. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

Lubricate with clean engine oil and install the crankshaft upper main bearings into the cylinder block.





6. Install the crankshaft onto the upper thrust bearing and main bearings.





7. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).

Install the rear main bearing cap.





8. Install the crankshaft lower main bearings, thrust bearing and thrust washer into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or dead-blow hammer.





9. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.





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

Tighten the bolts 1 through 20 in the sequence shown.





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





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





13. Tighten the bolts in the sequence shown.





14. Install and tighten the cross-mounted bolts in two stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stake 2: Tighten an additional 90 degrees.
15. Check the piston to cylinder block and piston ring clearances.





16. Install the piston rings.





17. Position the piston rings as illustrated.





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

NOTE: The piston installation steps are for all eight connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.

Use the special tools to install the connecting rod with upper connecting rod bearing in place.
^ Lubricate the piston and ring with clean engine oil.
^ Lubricate the rod bearings with clean engine oil.





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

Once the connecting rod is seated on the crankshaft journal, remove the special tool.

20. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod cap, and install the new bolts loosely.





21. NOTE: Main caps are not shown for clarity.

Tighten the bolts in three stages, using the sequence shown.
^ Stage 1: Tighten to 23 Nm (17 ft. lbs.).
^ Stage 2: Tighten to 43 Nm (32 ft. lbs.).
^ Stage 3: Tighten an additional 90-120 degrees.





22. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.





23. CAUTION: Make sure all coolant residue and foreign material is cleaned from the block surface and the cylinder bore.

CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean.

CAUTION: The use of the sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.

NOTE: RH shown, LH similar.

Install the head gaskets over the dowel pins.





24. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.

CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.

Tighten the LH cylinder head bolts in six stages in the sequence shown.
1. Tighten the bolts to 40 Nm (30 ft. lbs.).
2. Tighten the bolts an additional 90 degrees (1/4 turn).
3. Back out all the bolts one full turn (360 degrees).
4. Tighten the bolts to 40 Nm (30 ft. lbs.).
5. Tighten the bolts an additional 90 degrees (1/4 turn).
6. Tighten the bolts an additional 90 degrees (1/4 turn).





25. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.

CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.

Tighten the RH cylinder head bolts in six stage; in the sequence shown.
1. Tighten the bolts to 40 Nm (30 ft. lbs.).
2. Tighten the bolts an additional 90 degrees (1/4 turn).
3. Back out all the bolts one full turn (360 degrees).
4. Tighten the bolts to 40 Nm (30 ft. lbs.).
5. Tighten the bolts an additional 90 degrees (1/4 turn).
6. Tighten the bolts an additional 90 degrees (1/4 turn).





26. NOTE: Lubricate O-ring seal with clean engine oil.

Install the oil level indicator tube.
^ Install a new O-ring seal on the oil level indicator tube.
^ Install the oil level indicator tube.
^ Install the bolt.





27. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.





28. Install the RH exhaust manifold heat shield and the bolts.





29. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.





30. Install the LH exhaust manifold heat shield and the bolts.





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

CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Compress the tensioner plunger, using an edge of a vise.





32. Using a small screwdriver or pick, push back and hold the ratchet mechanism.





33. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





34. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
35. Remove the tensioner from the vise.





36. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.





37. Position the crankshaft with the special tool.





38. Install the crankshaft sprocket, make sure the timing mark faces forward.





39. Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the bolts.
3. Position the RH timing chain guide.
4. Install and tighten the bolts.





40. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.





41. Install the timing chains.
^ Install the LH (inner) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket.
^ Install the LH (inner) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket.
^ Install the RH (outer) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket.
^ Install the RH (outer) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket.





42. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole, for identification.

Position the LH and RH timing chain tensioner arm on the dowel pins.





43. Position the RH timing chain tensioner and install the bolts.





44. Position the LH timing chain tensioner and install the bolts.





45. Remove both the RH and LH retaining pins from the timing chain tensioners.





46. As a post-check, make sure the copper (marked) links on the timing chains line up with the timing marks on the crankshaft and camshaft sprockets.