Crankshaft

Removal

1. Remove engine from vehicle as outlined.

2. Mount engine in a suitable work stand. Drain crankcase and cylinder block cooling jackets.

3. Disconnect ignition wire from the spark plugs (12405) .

4. Remove spark plugs .

5. Remove oil pan (6675) and oil pump screen cover and tube (6622) .

6. Remove engine front cover (6019) and water pump (8501) as an assembly.

7. Remove distributor drive gear (6255).

8. Remove crankshaft sprocket (6306) , camshaft sprocket (6256) and timing chain.

9. Remove flywheel (6375) and engine rear plate (7007) as outlined.

10. Remove connecting rod caps. Turn crankshaft (6303) as necessary to position connecting rod (6200) in the low point of travel before removing connecting rod cap.

    Push piston (6108) up into cylinder block bore after removing connecting rod cap. Ensure crankshaft journals are not damaged.

    Each connecting rod cap should be identified so it can be installed in its original position during assembly.

11. Remove crankshaft main bearing caps.

    NOTE: Handle crankshaft with care to prevent possible damage to finished bearing surfaces.

12. Carefully lift crankshaft out of cylinder block (6010) to prevent damage to bearing surfaces.

13. Remove crankshaft rear oil seal (6701) and discard.

    Refer to Section 03-00 for crankshaft cleaning, inspection and refinishing.

     CAUTION: Because the engine crankshaft incorporates deep rolling of the main journal fillets, journal refinishing is limited to 0.25mm (0.010 inch) undersize standard journal dimensions. Further crankshaft main journal refinishing may result in fatigue failure of the crankshaft.

    
    
    
    
    
    

    Item	Part Number	Description
    1A	N805417-S	Stud Bolt
    2	—	Rear Main Bearing Cap (Part of 6010)
    3	—	Rear Intermediate Main Bearing Cap (Part of 6010)
    4	6337	Crankshaft Thrust Main Bearing—Lower
    5	6333	Crankshaft Main Bearing—Upper (3 Req'd)
    6	6337	Crankshaft Thrust Main Bearing—Upper
    7	6010	Cylinder Block
    8	6303	Crankshaft
    9	6333	Crankshaft Main Bearing—Lower (3 Req'd)
    10	—	Front Main Bearing Cap (Part of 6010)
    11	—	Front Intermediate Main Bearing Cap (Part of 6010)
    12A	N806845-S	Bolt (7 Req'd)
    A		Tighten to 110-120 Nm (81-89 Lb-Ft)

Installation

Lightly oil all bolts and stud threads before installation.

 CAUTION: Contaminants on a bearing surface will cause damage to the crankshaft journals.

1. Ensure all crankshaft bearing surfaces and crankshaft main bearings are clean.

2. If crankshaft main bearing journals have been refinished to definite undersize, remove crankshaft main bearings from cylinder block and main bearing caps.

   Loosen the lower intake manifold retaining bolts and support brackets prior to installing bearings or measuring bearing clearances.

   Install new crankshaft main bearings. Ensure tabs on bearing engages slots in the main cap and cylinder block .

3. Ensure crankshaft rear oil seal groove in cylinder block is clean.

4. Carefully lower crankshaft into position in cylinder block . Be careful not to damage crankshaft thrust bearing.

5. Ensure crankshaft rear oil seal groove in rear main bearing cap is clean.

   NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced.

6. Apply a 3mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to rear main bearing cap-to-cylinder block parting line.

7. Lubricate bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install main bearing caps and retaining bolts.

8. Tighten main bearing cap retaining bolts as follows:
   1. Wedge a screwdriver between cylinder block web and crankshaft cheek in front of the No. 3 crankshaft main bearing.

      Do not jam the screwdriver into position. Carefully tap on the screwdriver until it holds crankshaft toward front of engine.

   2. Tighten main bearing cap retaining bolts to 110-120 Nm (81-89 lb-ft).
   3. Remove screwdriver.

9. Check crankshaft end play as outlined in Section 03-00.

10. Install crankshaft rear oil seal as outlined.

11. If crankshaft connecting rod journals have been refinished to a definite undersize, remove connecting rod bearings from connecting rods and connecting rod caps.

    Install new connecting rod bearings. Ensure tabs on bearing securely engage the slots in connecting rod and cap.

12. Rotate cylinder block as necessary to bring each crankshaft throw to lowest point of travel. Pull piston downward until connecting rod seats on crankshaft throw and install connecting rod caps.

13. Check connecting rod clearance. Refer to Section 03-00.

    As each clearance check is completed lubricate bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installing connecting rod cap.

    Tighten retaining nuts to 41-49 Nm (31-36 lb-ft), back-off nuts two to three turns. Final-tighten the nuts to 41-49 Nm (31-36 lb-ft).

14. Install timing chain and engine front cover/ water pump assembly as outlined.

15. Install camshaft position sensor (CMP sensor) (6B288) as outlined in Section 03-14.

16. Install oil pan as outlined.

17. Install engine rear plate and flywheel as outlined.

18. Install spark plugs .

19. Connect ignition wires to spark plugs .

20. Install engine in the vehicle as outlined.