Steps 1 - 60

Special Tools:

1. WARNING: Eye protection is required to be worn during the use of compressed air. Failure to follow these instructions may result in possible personal injury.

Note: If required, deglaze the cylinder walls using a suitable spring-type tool. Clean the cylinder walls with a detergent and water solution upside-down to prevent contamination of the lower portion of the cylinder block.

Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.
2. Install the cup plugs, block dowels or pipe plugs that may have been removed during disassembly. Tighten the pipe plugs as follows:
- 3/8-18 inch to 20 Nm (15 ft. lbs.) + 180°
- 1/2-14 inch to 40 Nm (30 ft. lbs.) + 180°
- 3/4-14 inch to 10 Nm (89 inch lbs.) + 720° or 40 Nm (30 ft. lbs.), whichever comes first. Do not exceed 720° or 40 Nm (30 ft. lbs.).
3. Measure the cylinder bore diameter and compare to specification. Cylinder bore measurements should be taken within 50 mm (2 inch) from the top of the bore. Mark the outside of the block with the appropriate bore grade number for the replacement piston. Replacement pistons and domes are marked with grade numbers.

4. If removed, install cup plugs. Apply a 2 mm (0.08 inch) bead of sealant meeting Ford specification WSK-M2G349-A7 to the cup plug prior to installation.
5. If removed, install the engine block heater.

6. If removed, install the crankshaft key into the keyway on the crankshaft.

7. Note: This procedure is for selecting bearings using a new crankshaft.

Select the crankshaft main bearings for each crankshaft journal.
1 Read the code on the crankshaft flange.
2 Read the code on the cylinder block rear face.
- The first two numbers after the asterisk make up the coder for main No. 1 and the next two numbers for main No. 2.
- The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.

8. Look at the Select-Fit Chart and for each main, match the block and crankshaft code with its corresponding column or row, by reading across the crankshaft row and down the block column. Select the proper grade bearing for each main.
For example: If the block code is *0609*0711* and the crankshaft code is *8480*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 84 crankshaft row. Main Nos. 2, 3 and 4 should all be grade 2.

9. Install the upper main bearing and upper thrust bearing into the cylinder block in the correct locations.

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

Carefully install the crankshaft into the cylinder block.

11. Install the lower main bearings and lower thrust bearing into the lower cylinder block in the correct locations.

12. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which may make leak paths. Use a plastic scraper to remove all traces of old sealant.

Note: Both sealing surfaces must be clean, dry and free of any dirt or other contamination prior to application of the sealant. Use Metal Surface Cleaner F4A7-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Note: The lower cylinder block and bolts, with all bolts tightened, must be assembled within four minutes of applying sealer.

Apply a 3 mm (0.12 inch) bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the lower cylinder block ending 6 mm (0.24 inch) from the rear crankshaft seal bore on both sides.

13. Install the lower cylinder block and bolts.
- Tighten the bolts in the sequence shown in four stages.
- Stage 1: Tighten numbers 1 through 8 to 25 Nm (18 ft. lbs.).
- Stage 2: Tighten numbers 9 through 16 to 40 Nm (30 ft. lbs.).
- Stage 3: Rotate numbers 1 through 16 an additional 90°.
- Stage 4: Tighten numbers 17 through 22 to 25 Nm (18 ft. lbs.).
14. Remove the squeezed out seater at the engine front cover surface and the rear seal bore inner diameter.
15. Check crankshaft end play.

16. CAUTION: Rotating the crankshaft in a counterclockwise direction may cause engine damage. Crankshaft journals are directionally machined. Rotating the crankshaft counterclockwise can raise burrs on bearing surfaces, reducing engine life.

Rotate the crankshaft clockwise to verify free rotation.

17. Note: Apply Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to the crankshaft flange outer diameter and to the crankshaft seal bore inner diameter prior to seal installation.

Using the special tool, install the crankshaft rear oil seal.
18. Select the correct size connecting rod bearings.

19. Note: The connecting rod bearing tangs should align with the notch in the connecting rod and cap.

Install the connecting rod bearings into the connecting rods and connecting rod caps.

20. CAUTION: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

Note: Lubricate the pistons, piston rings, connecting rod bearings and entire cylinder bores with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation.

Note: Check piston rings for correct orientation prior to installing piston into cylinder bore.

Note: Install pistons with arrows on pistons to front of engine.

Note: After installation of each piston and connecting rod, rotate the crankshaft to verify smooth operation.

Turn the crankshaft until the crankshaft throw is at the bottom of the stroke. Using the special tools, install the piston, connecting rod, and connecting rod bearing assemblies Nos. 1 and 4. Tighten the bolts in three stages:
- Stage 1: Tighten to 23 Nm (17 ft. lbs.).
- Stage 2: Tighten to 43 Nm (32 ft. lbs.)
- Stage 3: Tighten an additional 90°.
21. Install the piston, connecting rod and connecting rod bearing assemblies Nos. 2 and 5. Tighten the bolts in three stages:
- Stage 1: Tighten to 23 Nm (17 ft. lbs.).
- Stage 2: Tighten to 43 Nm (32 ft. lbs.).
- Stage 3: Tighten an additional 90°.
22. Install the piston, connecting rod and connecting rod bearing assemblies Nos. 3 and 6. Tighten the bolts in three stages:
- Stage 1: Tighten to 23 Nm (17 ft. lbs.).
- Stage 2: Tighten to 43 Nm (32 ft. lbs.).
- Stage 3: Tighten an additional 90°.
23. Check the connecting rod side clearance for all of the connecting rods.

24. Rotate the crankshaft to position the keyway at the nine o'clock position.

25. Position the oil pump and install the bolts.

26. Position the oil pan baffle and install the nuts. Tighten in two stages:
- Stage 1: Tighten to 5 Nm (44 inch lbs.).
- Stage 2: Tighten an additional 45°.

27. Position the oil pump screen cover and tube and install the bolts.
- Use a new O-ring seal if necessary.

28. Position the top-mounted KS and install the bolt.

29. Position the side-mounted KS and install the nut.

30. Using a new gasket, position the oil separator and install the bolts.

31. Using anew O-ring seal, position the coolant inlet tube and install the bolts.

32. CAUTION: The cylinder head gasket surfaces are ground to a precision finish. Do not rest cylinder heads on gasket surfaces. Do not use any abrasive during cleaning of the surfaces. Hairline scratches, small burrs, or dirt can provide a leak path for a cylinder head gasket to leak. If gasket material remains on the sealing surface, use only a plastic-tipped scraper to remove the material. Do not attempt to reuse the head gaskets.

CAUTION: Cylinder head bolts are torque-to-yield and cannot be reused. Note: The LH and RH cylinder head gaskets are not interchangeable.

Using a new cylinder head gasket, position the RH cylinder head, and install the bolts.
- Tighten the bolts in six stages:
- Stage 1: Tighten to 30 Nm (22 ft. lbs.).
- Stage 2: Tighten an additional 90°.
- Stage 3: Back out a minimum of one full turn (360°).
- Stage 4: Tighten to 30 Nm (22 ft. lbs.).
- Stage 5: Tighten an additional 90°.
- Stage 6: Tighten an additional 90°.

33. Using a new cylinder head gasket, position the LH cylinder head, and install the bolts.
- Tighten the bolts in six stages:
- Stage 1: Tighten to 30 Nm (22 ft. lbs.).
- Stage 2: Tighten an additional 90°.
- Stage 3: Back out a minimum of one full turn (360°).
- Stage 4: Tighten to 30 Nm (22 ft. lbs.).
- Stage 5: Tighten an additional 90°.
- Stage 6: Tighten an additional 90°.

34. CAUTION: The tappets and shims must be installed in their original positions.

CAUTION: The bucket tappets and bores must be absolutely clean prior to bucket tappet installation. Failure to correctly dean these components may result in a sticking valve leading to severe engine damage or failure.

Note: Only lightly lubricate the tappet shim prior to installation. Excess oil on the tappet shim may cause inaccurate valve clearance measurements.

Note: LH side shown; RH side similar.

Lubricate all of the valve tappets, shims and bores and install them in their original positions.
- Lubricate the valve tappets and bores with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2CI53-G.
- Lubricate the shims with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2CI53-G.

35. Note: Be sure camshaft bearing caps are installed in their original positions.

Lubricate the LH camshafts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G and carefully position the camshaft into the LH cylinder head.

36. CAUTION: This is not a free-spinning engine. The crankshaft keyway must be at the nine o'clock position prior to tightening the camshaft caps or rotating the camshafts. Failure to follow these directions may result in serious engine damage.

CAUTION: Cylinder head camshaft journal caps are numbered. Keep camshaft journal caps with the cylinder head from which they were removed. Do not mix with camshaft journal caps from another cylinder head.

CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing journal. caps have been tightened, or damage to the thrust caps may occur.

Lubricate the LH camshaft bearing journal caps with Super Premium SAE SW-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Position the caps in their correct locations and loosely install the bolts.

37. Lubricate the LH camshaft thrust caps with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G and position the caps and loosely install the bolts.

38. Tighten the bolts in sequence shown.

39. Lubricate the RH camshafts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G and carefully position the camshaft into the RH cylinder head.

40. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to make sure they are installed in their original position. Keep camshaft journal caps with the cylinder head from which they were removed. Do not mix with camshaft journal caps from another cylinder head.

CAUTION: Do not install the camshaft journal thrust caps until all of the camshaft bearing journal caps have been tightened or damage to the thrust caps may occur.

Lubricate the camshaft bearing journal caps with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M20 53-G. Position the caps in their correct locations and loosely install the bolts.

41. Lubricate the R11 camshaft thrust caps with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G and loosely install the caps and bolts.

42. Tighten the camshaft journal cap bolts in the sequence shown.

43. CAUTION: The crankshaft keyway must remain in the nine o'clock position until the cams are located, or damage to the valves may occur.

Rotate each camshaft to make sure there is smooth rotation and to position the cams in their neutral position.
44. Install the crankshaft pulley and tighten the bolt.

45. Rotate the crankshaft clockwise to position the keyway to the 11 o'clock position.
46. Remove the bolt and the crankshaft pulley.

47. Position the LH chain tensioner in a soft-jawed vise.

48. Hold the chain LH tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

49. CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Slowly compress the LH timing chain tensioner.

50. Note: The wire must remain in the timing chain tensioner until the tensioner is installed.

Retain the LH tensioner piston with a 1.5 mm (0.06 inch) wire or paper clip.

51. Install the LH timing chain guide.
1 Position the guide to the engine.
2 Install the shorter (gold color) bolt into the upper hole.
3 Install the longer bolt (black color) into the lower hole.

52. Install the LH timing chain, aligning the timing index link (gold color) with the marks on the camshaft and crankshaft sprockets.

53. Note: Be sure to position the tensioner so that the tensioner piston is fully engaged in the tensioner arm.

Install the LH tensioner arm, tensioner and tensioner bolts.

54. Remove the wire or paper clip from the tensioner.

55. Rotate the crankshaft clockwise and position the keyway between the 2 o'clock and 3 o'clock positions for RH timing chain installation.

56. Verify that the timing index links (gold color) on the LH timing chain are in alignment with the timing index marks on the camshaft and crankshaft sprockets.

57. Position the RH chain tensioner in a soft-jawed. vise.

58. Hold the RH chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

59. CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Slowly compress the RH timing chain tensioner.

60. Note: The wire must remain in the timing chain tensioner until the tensioner is installed.

Retain the RH tensioner piston with a 1.5 mm (0.06 inch) wire or paper clip.