Engine

Disassembly

Before starting disassembly, remove accessories and any emission control equipment which is not directly attached to the engine.

1. Remove flywheel (6375) and engine rear plate (7007) .

2. Remove intake manifolds (9424) .

   When LH exhaust manifold (9430) is removed, note location of oil level indicator tube support bracket.

   If necessary, heated oxygen sensors (HO2S) (9F472) can be removed from exhaust manifolds .

3. Disconnect front fuel vapor hose and remove the following positive crankcase ventilation system components:
   • Front and rear crankcase ventilation tube (6758) .
   • Positive crankcase ventilation valve (PCV valve) (6A666).

4. Disconnect water bypass tube or hose (8548) and water bypass hose (8597) at intake manifold . Remove heater water outlet tube retaining bolts and heater water outlet tube (18663) from water pump (8501).

   NOTE: When removing an ignition wire from a spark plug, use Spark Plug Wire Remover T74P-6666-A. Grasp and twist boot back and forth on plug insulator to free boot. Use tool to pull boot from spark plug. Do not pull on ignition wire directly or it may become separated from connector inside boot.

5. Disconnect ignition wires from spark plugs (12405) .

6. Remove the following components:
   • Throttle body (9E926) and throttle body gasket (9E936) .
   • EGR valve (EGR valve) (9D475).
   • Upper intake manifold and intake manifold upper gasket (9H486) .
   • Fuel injectors (9F593) and fuel injection supply manifold (9F792) .

   NOTE: If the crankshaft pulley and vibration damper have to be separated, mark the damper and pulley so that they may be reassembled in the same relative position. This is important as the damper and pulley are initially balanced as an assembly.

7. Remove crankshaft pulley and vibration damper. Use Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B to remove vibration damper.

   NOTE: If the crankshaft damper is being replaced, check if the original damper has balance pins installed. If so, new balance pins (E0SZ-6A328-A or equivalent) must be installed on the new damper in the same position as the original damper. The crankshaft pulley (new or original) must also be installed in the same relative position as originally installed.

8. Remove hold-down clamp (12270) and camshaft position sensor (CMP sensor) (6B288) .

9. Remove valve covers (6582).

   NOTE: Before attempting to remove lower intake manifold , break seal between intake manifold and cylinder block (6010) . Wedge a large screwdriver between intake manifold and cylinder block . Pry downward on screwdriver using lug on water pump as a leverage point.

10. Remove lower intake manifold and intake manifold gasket (9439) . Discard intake intake manifold gasket and end seals.

     CAUTION: Do not damage machined surfaces.

11. Remove spark plugs.

12. Remove rocker arms (6564) and push rods (6565) . The location of each rocker arm , push rod and fulcrum should be noted. When engine is assembled, each component should be installed in its original position.

13. Remove cylinder head (6049). Discard cylinder head retaining bolts. Remove and discard head gaskets (6051) .

14. Remove tappet guide plates and retainers (6K564) , valve tappet guide plates (6K512) and valve tappets (6500) .

    The location of each valve tappet should be identified. When engine is assembled, each valve tappet should be installed in its original position. If valve tappets are stuck in bores due to excessive varnish or gum deposits, it may be necessary to use a magnet or a claw-type tool to aid removal. When using a remover tool, rotate valve tappet back and forth to loosen it from any gum or varnish that may have formed on valve tappet .

15. Remove oil bypass filter (6714).

16. Remove oil pan (6675). Remove RTV gasket.

17. Remove oil pump screen cover and tube (6622) . Discard oil pump inlet tube gasket (6626) .

18. Remove water pump and engine front cover (6019) as an assembly. Remove and discard engine timing cover gasket (6020).

    After removing engine front cover, remove camshaft sprocket retaining bolt and washer from end of camshaft (6250) .

19. Remove distributor drive gear (6255). Remove camshaft sprocket (6256) , crankshaft sprocket (6306) and timing chain.

     CAUTION: Do not damage finished areas on crankshaft (6303) and crankshaft sprocket .

    NOTE: If crankshaft sprocket is difficult to remove, it can be pried off using two large screwdrivers.

    
    
    
    
    

20. Remove two spacers.

21. Remove camshaft thrust plate (6269).

     CAUTION: Do not damage camshaft bearing surfaces.

22. Remove camshaft.

23. If necessary, remove camshaft rear bearing cover (6266) from back of engine.

     CAUTION: Never cut into ring travel area in excess of 0.794mm (0.0325 inch) or possible damage to piston rings or cylinder block may occur.

    NOTE: Before removing pistons (6108) , inspect top of cylinder bores. If necessary, remove ridge and/or carbon deposits from each cylinder using Rotunda Cylinder Ridge Reamer 014-00292 or equivalent. Before ridge or deposits are removed, turn crankshaft until piston is at bottom of its stroke. Cover piston with a clean shop towel to collect cuttings. After cutting operation, turn crankshaft until piston is at top of its stroke and remove shop towel with cuttings.

24. Remove connecting rod caps and pistons .
    
    
    
    

    The location of each piston, camshaft bearing and connecting rod cap should be noted. When engine is assembled each component should be installed in its original position.

25. Remove main bearing caps and crankshaft . The location of crankshaft main bearings should be identified. When engine is assembled, each bearing should be installed in its original position.

26. For cleaning purposes, oil gallery and cooling jacket plugs can be removed.

Assembly

NOTE: During engine assembly, an RTV-type sealer will be applied to many components 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 threads before installation except those specifying special sealant.

1. If removed, install oil gallery and cooling jacket plugs. Tighten plugs to specification.

   Before installation, coat plug threads with Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-AZ and ESR-M18P7-A.

   To provide clearance for camshaft sprocket, oil gallery plugs on front of engine must be threaded below machined surface.

2. Install crankshaft as follows:
   1. Install crankshaft main bearings in cylinder block . Note that third bearing from front is the thrust bearing.
   2. Lubricate bearing inserts with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A, and carefully lower crankshaft into place. Use care to prevent damage to bearing surfaces.
   3. Apply a 3mm (1/8 inch) bead of Silicone Rubber, D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to cylinder block rear main bearing cap parting line.
   4. Install crankshaft main bearings in main caps and install caps. Note that caps are numbered with triangles. Cap No. 1 is located at the front of engine with triangle facing front of engine.
   5. Install main bearing cap retaining bolts.

       CAUTION: Do not jam screwdriver into place. Tap into position only enough to hold crankshaft forward while cap bolts are tightened.

   6. Before tightening bearing cap retaining bolts, wedge a large screwdriver between cylinder block web and crankshaft cheek located in front of No. 3 main bearing.
   7. Tighten bearing cap retaining bolts to 110-120 Nm (81-89 lb-ft) and remove screwdriver.

3. Check crankshaft end play. Refer to Section 03-00.

4. Install pistons as follows:
   1. Install connecting rod bearings in connecting rods (6200) and connecting rod caps.
   2. Install pistons using Rotunda Piston Ring Compressor 014-00290 or equivalent. The notch in piston dome must face the front of engine.

      Lubricate piston and cylinder walls with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installation.

      NOTE: Scratching of crankshaft journal can be prevented by covering connecting rod bolts with ignition wire spark plug boots or flexible hose.

      
      
      
      
      
      
      
      
      
   3. Install connecting rod caps and retaining nuts as follows:
      • Tighten retaining nuts to 41-49 Nm (31-36 lb-ft).
      • Loosen retaining nuts two to three revolutions.
      • Final tighten retaining bolts to 41-49 Nm (31-36 lb-ft).

5. Check connecting rod side clearance as outlined in Section 03-00.

6. Install camshaft rear bearing cover using a suitable driver.

   Coat sealing edge of plug with Perfect-Seal Sealing Compound B5A-19554-A or equivalent meeting Ford specifications ESR-M18P2-A and ESE-M4G115-A before installation.

7. Coat camshaft lobes and camshaft bearings with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

8. Install camshaft.

9. Install camshaft thrust plate and tighten retaining screws to 8-14 Nm (6-10 lb-ft).

10. Install timing chain vibration damper (6284) . Tighten retaining screws to 8-14 Nm (6-10 lb-ft).

11. Install balance shaft spacers.

12. Lubricate timing chain with clean engine oil.

13. Rotate crankshaft, as necessary, to position crankshaft sprocket keyway in 12 o'clock position.

14. Install camshaft sprocket, crankshaft sprocket and timing chain.

    Ensure crankshaft keyway, camshaft sprocket timing mark and crankshaft sprocket timing mark are properly aligned after installation.
    
    
    
    

15. Install distributor drive gear.

16. If water pump was removed from engine front cover during engine disassembly, position a new water pump housing gasket (8507) on engine front cover and install water pump .

    Tighten water pump retaining bolts to 20-30 Nm (15-22 lb-ft).

17. Install camshaft sprocket retaining bolt and washer. Tighten bolt to 40-50 Nm (30-37 lb-ft).

18. Position a new engine timing cover gasket on engine. Install engine front cover . Tighten retaining bolts to 20-30 Nm (15-22 lb-ft).

19. Install oil pump screen cover and tube using a new oil pump inlet tube gasket .

    Tighten retaining bolts to 20-30 Nm (15-22 lb-ft), and support bracket retaining nut to 40-55 Nm (30-40 lb-ft).

20. Install oil pan as follows:

    NOTE: Using solvent, clean oil pan and cylinder block seating surfaces before applying silicone sealer.

    1. Using a small-blade screwdriver remove any sealer which may have been squeezed into seal groove when rear main bearing cap was installed. Place a 6.35mm (1/4 inch) bead of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A into seal groove where bearing cap meets cylinder block .
    2. Apply a 3mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to seams where engine front cover mates with cylinder block and to each end of oil pan end seal.
    3. Apply RTV gasket material in a zig-zag pattern on cylinder block .
    4. Install oil pan. Tighten retaining bolts to 9-12 Nm (80-106 lb-in).

21. Lubricate oil bypass filter gasket with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

    Thread oil bypass filter onto adapter until gasket contacts cylinder block and then advance oil bypass filter an additional one-half turn.

22. Lubricate valve tappets with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A, and install.

23. Install six valve tappet guide plates and two tappet guide plates and retainers . Tighten tappet guide plate and retainer retaining bolts to 10-14 Nm (7-10 lb-ft).

24. Install new head gaskets using cylinder head to block dowels (6A008) to align head gasket .
    
    
    
    

25. Install cylinder head as outlined under Cylinder Head , Removal and Installation.

26. Install push rods, rocker arms , fulcrums and retaining bolts. Lubricate push rod ends and fulcrums with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installation.

    For each valve, rotate crankshaft until valve tappet rests on heel (base circle) of camshaft lobe. Tighten fulcrum retaining bolt to 9-20 Nm (7-15 lb-ft). Final-tighten fulcrum retaining bolts to 25-35 Nm (19-25 lb-ft). For final tightening, camshaft may be in any position.

27. Install lower intake manifold as outlined under Upper and Lower Intake Manifolds , Removal and Installation.

28. Install spark plugs. Tighten to 9-20 Nm (7-15 lb-ft).

29. Install valve covers as follows:

    NOTE: Using solvent, clean valve cover and cylinder head sealing surfaces to remove all gasket material and dirt.

    1. Install a new valve cover gasket (6584) onto cylinder head .
    2. Install valve cover and retaining bolts. Note location of stud/bolts.
    3. Tighten retaining bolts to 9-12 Nm (7-9 lb-ft).

30. Install camshaft position sensor and hold-down clamp as outlined in Section 03-07B.

31. Install crankshaft pulley and vibration damper using Damper/Front Cover Seal Installer T82L-6316-A and Front Cover Seal Installer T70P-6B070-A. Tighten retaining bolt to 140-180 Nm (103-132 lb-ft).

32. Install fuel injector and fuel injection supply manifold . Tighten retaining bolts for fuel injection supply manifold bracket to 8-11 Nm (6-8 lb-ft).

33. Connect the front fuel vapor tube and install the following positive crankcase ventilation system components:
    • Front and rear crankcase ventilation tube.
    • Positive crankcase ventilation valve.

34. Install upper intake manifold. Tighten bolts and studs in sequence in three steps:
    1. 10 Nm (8 lb-ft).
    2. 20 Nm (15 lb-ft).
    3. 32 Nm (24 lb-ft).

35. Install EGR valve. Tighten bolts to 30-46 Nm (15-22 lb-ft).

36. Connect ignition wires to spark plugs.

37. Inspect heater water outlet tube O-ring (replace as necessary) and install heater water outlet tube . Install and tighten retaining bolts to 8-12 Nm (71-106 lb-in).

38. Install water bypass tube or hose to intake manifold . Tighten hose clamp securely.

39. Install exhaust manifolds. Note location of oil level indicator tube support bracket. Tighten exhaust manifold retaining bolts to 30-36 Nm (22-46 lb-ft).

40. Install engine rear plate and flywheel .

    Apply a thin coat of Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-AZ and ESR-M18P7-A to flywheel retaining bolt threads before installation.

    Tighten flywheel bolts to 73-87 Nm (54-64 lb-ft) in standard cross-tightening sequence.