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Engine - Early Build: Assembly

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    NOTE: Check alignment of the oil holes after installing the bearings.
    Fig 1: Installing Camshaft Bearings
    G03899983Courtesy of FORD MOTOR CO.
  1. If removed, install the camshaft bearings.
    2. CAUTION: The patch bolt is unique - do not substitute or engine damage can occur.
    NOTE: Apply Threadlock 262® to the threads prior to installation.
    Fig 2: Installing Eight Piston Cooling Tubes Bolts
    G03899984Courtesy of FORD MOTOR CO.
  2. Install the eight piston cooling tubes and bolts.
    3. CAUTION: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage can occur.
    NOTE: Apply clean engine oil to the camshaft prior to installing.
    Fig 3: Installing Camshaft Gear Assembly
    G03899985Courtesy of FORD MOTOR CO.
  3. Install the camshaft and gear assembly. Install the thrust plate mounting bolts.
    4. NOTE: Apply clean engine oil to all the bearings.
    Fig 4: View Of Crankshaft Upper Bearing Seats
    G03887601Courtesy of FORD MOTOR CO.
  4. Install the crankshaft upper bearings and the crankshaft upper thrust bearing.
  5. Using the special tool, align the camshaft timing mark as shown.
    Fig 5: Aligning Camshaft Timing Mark
    G03899987Courtesy of FORD MOTOR CO.
  6. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.
    Fig 6: Installing Crankshaft
    G03899988Courtesy of FORD MOTOR CO.
    7. NOTE: Do not turn the crankshaft during the main bearing clearance check.
  7. Position commercially available plastigage in the center of each main bearing bolt cap.
  8. Install the lower bearings into the lower crankcase.
    Fig 7: Installing Lower Bearings Into Lower Crankcase
    G03899989Courtesy of FORD MOTOR CO.
    9. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
  9. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in the following sequence.
    1. Tighten bolts to 149 N.m (110 lb-ft) in numerical sequence.
    2. Tighten bolts again to 176 N.m (130 lb-ft) in numerical sequence.
    3. Tighten bolts to 231 N.m (170 lb-ft) in the numerical sequence.
      4. Fig 8: Lower Crankcase Main Bearing Mounting Bolts Tightening Sequence
      G03899990Courtesy of FORD MOTOR CO.
  10. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.
    Fig 9: Tightening Bolts In Sequence
    G03899991Courtesy of FORD MOTOR CO.
  11. Remove the 28 bolts and the lower crankcase.
    Fig 10: Locating Lower Crankcase Bolts
    G03887598Courtesy of FORD MOTOR CO.
  12. Measure the clearances for the main bearings. Remove the plastigage.
    Fig 11: Measuring Clearances
    G03899993Courtesy of FORD MOTOR CO.
    13. NOTE: Apply clean engine oil to the lower main bearings.
    Fig 12: Locating Lower Crankcase Seals
    G03887599Courtesy of FORD MOTOR CO.
  13. Install new lower crankcase seals.
    14. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
    Fig 13: Lower Crankshaft Main Bearing Bolt Tightening Sequence
    G03887639Courtesy of FORD MOTOR CO.
  14. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten mounting bolts in the following sequence.
    1. Tighten bolts to 149 N.m (110 lb-ft) in numerical sequence.
    2. Tighten bolts again to 176 N.m (130 lb-ft) in numerical sequence.
    3. Tighten bolts to 231 N.m (170 lb-ft) in the numerical sequence.
  15. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.
    Fig 14: Tightening Bolts In Sequence
    G03899996Courtesy of FORD MOTOR CO.
    16. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
    Fig 15: Measuring Crankshaft End Play
    G03899997Courtesy of FORD MOTOR CO.
  16. Install the special tool and measure the crankshaft end play.
  17. Install the special tool and measure the camshaft end play.
    Fig 16: Measuring Camshaft End Play
    G03887593Courtesy of FORD MOTOR CO.
  18. Install the special tool and measure the camshaft gear backlash.
    Fig 17: Measuring Camshaft Gear Backlash
    G03887592Courtesy of FORD MOTOR CO.
  19. Install the block heater.
    Fig 18: Installing Block Heater
    G03900000Courtesy of FORD MOTOR CO.
  20. Install the camshaft position (CMP) sensor and the bolt.
    Fig 19: Installing Camshaft Position Sensor And Bolt
    G03900001Courtesy of FORD MOTOR CO.
  21. Install the crankshaft position (CKP) sensor and the bolt.
    Fig 20: Installing Crankshaft Position Sensor And Bolt
    G03900002Courtesy of FORD MOTOR CO.
    22. NOTE: Lubricate with clean engine oil.
    Fig 21: View Of Upper And Lower Connecting Rod Bearings
    G03887591Courtesy of FORD MOTOR CO.
  22. Install the connecting rod bearings.
    23. NOTE: Make sure the ring openings are 120 degrees from each other, or engine damage can occur.
    Fig 22: Identifying Piston Rings
    G03887590Courtesy of FORD MOTOR CO.
  23. Install new piston rings.
    1. The top compression ring is identified with one indentation mark and a 15 degree keystone profile.
    2. The intermediate compression ring is identified with two indentation marks and a square profile.
    3. Install the oil control ring.
    24. NOTE: Cam V8 is toward the inside of the engine.
    NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
    Fig 23: Pushing Connecting Rod And Piston Assembly Down Into Cylinder Bore
    G03900005Courtesy of FORD MOTOR CO.
  24. Install the piston and rod assemblies.
    1. Coat the inside diameter of the ring compressor with clean engine oil.
    2. Insert the piston into the special tool. Position the piston, connecting rod and special tool into the correct cylinder bore.
    • Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.
  25. Position a piece of Plastigage across the bearing surface.
    Fig 24: Positioning Piece Of Plastigage Across Bearing Surface
    G03900006Courtesy of FORD MOTOR CO.
  26. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
    • Tighten to 45 N.m (33 lb-ft).
    • Tighten to 68 N.m (50 lb-ft).
    Fig 25: Identifying Connecting Rod Cap Bolts
    G03887588Courtesy of FORD MOTOR CO.
  27. Remove the bolts and the connecting rod cap.
  28. Measure the clearances for the connecting rod cap. Remove the Plastigage.
    Fig 26: Measuring Clearances For Connecting Rod Cap
    G03900008Courtesy of FORD MOTOR CO.
  29. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
    • Tighten to 45 N.m (33 lb-ft).
    • Tighten to 68 N.m (50 lb-ft).
    Fig 27: Identifying Connecting Rod Cap Bolts
    G03887588Courtesy of FORD MOTOR CO.
  30. Using a feeler gauge, check for connecting rod side clearance.
    Fig 28: Checking Connecting Rod Side Clearance
    G04519326Courtesy of FORD MOTOR CO.
  31. Install the upper oil pan.
    • Install the upper oil pan gasket.
    • Install the upper oil pan.
    • Install the bolts.
    Fig 29: Installing Upper Oil Pan Bolts
    G03900011Courtesy of FORD MOTOR CO.
  32. Install the oil pick-up tube and screen.
    • Install a new O-ring.
    • Install the oil pick-up tube and screen.
    • Install the bolts.
    Fig 30: Installing Oil Pick-Up Tube Bolts
    G03900012Courtesy of FORD MOTOR CO.
  33. Install the oil pan.
    • Install the press-in-place gasket.
    • Install the oil pan.
    • Install the bolts.
    Fig 31: Installing Oil Pan Bolts
    G03900013Courtesy of FORD MOTOR CO.
    34. CAUTION: To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.
    NOTE: Only the front guides use bolts.
    Fig 32: Installing Roller Follower Guide Bolts
    G03900014Courtesy of FORD MOTOR CO.
  34. Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guide and the bolts.
  35. Install the rear engine tube assembly and the bolt.
    Fig 33: Installing Rear Engine Tube Assembly Bolt
    G03900015Courtesy of FORD MOTOR CO.
  36. Install the rear engine tube assembly bolts.
    Fig 34: Installing Rear Engine Tube Assembly Bolts
    G03900016Courtesy of FORD MOTOR CO.
  37. Install the four cylinder head dowels.
    Fig 35: Locating Cylinder Head Dowels
    G03887582Courtesy of FORD MOTOR CO.
    38. NOTE: Install a new cylinder head gasket with the part number facing up. Verify the top five bolt holes and the head gasket push rod holes line up.
    NOTE: Use care to avoid scratching the blue compound on the cylinder head gaskets.
    Fig 36: Identifying Gasket Sealing Surfaces Area
    G03887503Courtesy of FORD MOTOR CO.
  38. Place the new cylinder head gasket over the dowel sleeves and onto the crankcase.
  39. Using the special tool, install the cylinder heads.
    1. Install the lifting brackets.
    2. Install the bolts.
      • Install the cylinder heads.
    Fig 37: Identifying Special Tool And Cylinder Head
    G03887502Courtesy of FORD MOTOR CO.
  40. Install the 10 outer head bolts (finger-tight).
    Fig 38: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
    41. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
    NOTE: Higher mileage engines require push rods to be cleaned so the copper colored end of the push rod can be identified.
    NOTE: If a push rod has been replaced, it may not have a copper-colored end and can be installed with either end up.
    Fig 39: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  41. Apply clean engine oil to each end of the push rods. Insert them into them into their respective positions with the copper colored end up.
    42. NOTE: Coat the end of each valve stem with clean engine oil.
    Fig 40: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  42. Install the 16 valve bridges.
    43. NOTE: Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position.
    NOTE: Apply clean engine oil to the top center of each valve bridge.
    Fig 41: Locating Rocker Arm Assembly Bolts - With Torque Specification
    G03887670Courtesy of FORD MOTOR CO.
  43. Install the rocker arm assemblies and the 16 bolts.
    44. CAUTION: Using too much engine oil on the threads of the cylinder head bolts, can cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads can affect the true torque value of the bolts.
    NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
    Fig 42: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  44. Install the new cylinder head retaining bolts finger-tight.
  45. Tighten the head bolts in the following sequence.
    1. Tighten bolts 1 through 10 to 88 N.m (65 lb-ft).
    2. Tighten bolts 1 through 10 to 115 N.m (85 lb-ft).
    3. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
    4. Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
    5. Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
    6. Tighten bolts 11 through 15 to 24 N.m (18 lb-ft).
    7. Tighten bolts 11 through 15 to 31 N.m (23 lb-ft).
    Fig 43: Cylinder Head Bolt Tightening Sequence
    G03887672Courtesy of FORD MOTOR CO.
    46. NOTE: Install a new lower O-ring.
    Fig 44: Installing New Crankcase-To-Head Tube Assembly
    G03900026Courtesy of FORD MOTOR CO.
  46. Install a new crankcase-to-head tube assembly.
    47. CAUTION: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.
    NOTE: Lubricate the fuel injector and O-rings liberally with clean engine oil.
    Fig 45: Identifying O-Ring Seals, Copper Washer And Fuel Injector
    G03887397Courtesy of FORD MOTOR CO.
  47. Install new O-rings and a copper washer on the fuel injector.
    48. CAUTION: Failure to tighten the injector properly can lead to engine failure.
    CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The clip that extracts the injector can dislodge and fall into the oil drain hole.
    Fig 46: View Of Fuel Injector Hold-Down Clamp Bolt - With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  48. Install the fuel injector, the fuel injector hold-down and bolt.
    49. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage may occur.
    Fig 47: Identifying Fuel Injector Electrical Connector
    G03887399Courtesy of FORD MOTOR CO.
  49. Install the fuel injector electrical connector into the rocker carrier.
    50. NOTE: Apply clean engine oil to the top fuel injector O-rings before installing the high-pressure oil rail.
  50. Install the high-pressure oil rail.
    • Install the high-pressure oil rail.
    • Install the bolts finger-tight.
      Fig 48: Installing High-Pressure Oil Rail
      G03900030Courtesy of FORD MOTOR CO.
  51. Tighten the bolts in the sequence shown.
    Fig 49: Tightening Bolts In Sequence
    G03900031Courtesy of FORD MOTOR CO.
  52. Install the high-pressure oil line.
    Fig 50: Installing High-Pressure Oil Line
    G03900032Courtesy of FORD MOTOR CO.
  53. Apply a bead of sealant at the back seam of the upper and lower crankcase.
    Fig 51: Applying Sealant To Upper And Lower Crankcase
    G03887338Courtesy of FORD MOTOR CO.
  54. Install the rear engine cover.
    • Install the press-in-place gasket.
    • Install the rear engine cover.
    • Install the bolts.
    Fig 52: Installing Rear Engine Cover
    G03900034Courtesy of FORD MOTOR CO.
    55. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.
    NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant.
    NOTE: Apply a bead of Threadlock 262® around the circumference of the outer rear edge of the secondary crankshaft flange.
    Fig 53: Installing Crankshaft Rear Oil Seal Using Special Tool
    G03887293Courtesy of FORD MOTOR CO.
  55. Using the special tools, install the crankshaft rear oil seal.
  56. Install the flywheel adapter.
    Fig 54: Identifying Flywheel Adapter
    G03887288Courtesy of FORD MOTOR CO.
  57. If removed, install the front cover crankcase dowels into the cylinder block.
    Fig 55: Identifying Front Cover Crankcase Dowels
    G03887308Courtesy of FORD MOTOR CO.
  58. Apply a bead of sealant at the front seam of the upper and lower crankcase.
    Fig 56: Applying Bead Of Sealant
    G03900038Courtesy of FORD MOTOR CO.
    59. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
    Fig 57: Installing Guide Studs And Front Cover Gasket
    G03900039Courtesy of FORD MOTOR CO.
  59. Install the guide studs and the front cover gasket.
  60. Install the engine front cover and bolts.
    Fig 58: Installing Engine Front Cover Bolts
    G03900040Courtesy of FORD MOTOR CO.
    61. NOTE: Install oil drive rotors with marks pointing outward.
    Fig 59: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
    G03887281Courtesy of FORD MOTOR CO.
  61. Lubricate inner drive rotor with a suitable lithium assembly grease and install onto crankshaft. Lubricate outer drive rotor with lithium assembly grease and mesh with inner drive rotor in oil pump housing. Wipe off excess assembly grease.
    62. NOTE: Install a new O-ring seal.
    Fig 60: Installing Oil Pump Body Bolts
    G03900042Courtesy of FORD MOTOR CO.
  62. Install the oil pump body and the bolts.
    63. NOTE: Apply Threadlock 262® to the outer circumference of the leading edge of the crankshaft.
    NOTE: The seal and wear sleeve must not be separated.
    Fig 61: Installing Oil Seal And Wear Sleeve Assembly
    G03900043Courtesy of FORD MOTOR CO.
  63. Using the special tool, install the oil seal and wear sleeve assembly.
    64. CAUTION: To prevent engine damage, you must always install four new bolts when installing the vibration damper.
    NOTE: Do not use anti-seize compounds, grease, or any lubricants. Lubricants have an adverse effect on the torque results.
    Fig 62: Installing Crankshaft Vibration Damper Bolts
    G03900044Courtesy of FORD MOTOR CO.
  64. Install the crankshaft vibration damper and bolts.
    • Tighten the bolts in the sequence shown.
    • Tighten the bolts to 68 N.m (50 lb-ft).
    • Tighten the bolts an additional 90 degrees.
  65. If equipped, install the dual generator pulley and bolts.
    Fig 63: Installing Dual Generator Pulley Bolts
    G03900045Courtesy of FORD MOTOR CO.
    66. NOTE: Install a new O-ring on the coolant pump.
    Fig 64: Installing Coolant Pump Bolts
    G03900046Courtesy of FORD MOTOR CO.
  66. Install the coolant pump and bolts.
  67. Install the coolant pump pulley and the bolts.
    Fig 65: Installing Coolant Pump Pulley Bolts
    G03900047Courtesy of FORD MOTOR CO.
    68. CAUTION: To prevent engine damage, do not use air powered tools when installing the valve covers.
    NOTE: LH side shown, RH side similar.
    Fig 66: Installing Bolts And Stud Bolts
    G03900048Courtesy of FORD MOTOR CO.
  68. Install the valve covers.
    • Install the gaskets.
    • Install the valve covers.
    • Install the bolts and stud bolts.
  69. Install the eight glow plugs.
    Fig 67: Glow Plugs - With Torque Specification
    G03887699Courtesy of FORD MOTOR CO.
    70. NOTE: Left side shown, right side similar.
    NOTE: Clean and apply clean engine oil to the O-rings.
    Fig 68: Installing Glow Plug Buss Bar
    G03900050Courtesy of FORD MOTOR CO.
  70. Install the glow plug buss bar.
  71. Install a new O-ring seal.
    Fig 69: Installing New O-Ring Seal
    G03900051Courtesy of FORD MOTOR CO.
  72. Install the high-pressure oil pump and the bolts.
    Fig 70: Installing High-Pressure Oil Pump Bolts
    G03900052Courtesy of FORD MOTOR CO.
  73. Install the high-pressure pump O-ring seal.
    Fig 71: Installing High-Pressure Pump O-Ring Seal
    G03900053Courtesy of FORD MOTOR CO.
  74. Install the high-pressure discharge pipe and the bolts.
    Fig 72: Installing High-Pressure Discharge Pipe Bolts
    G03900054Courtesy of FORD MOTOR CO.
  75. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
    Fig 73: Positioning Dial Indicator With Bracketry
    G03900055Courtesy of FORD MOTOR CO.
  76. Install a new D-ring seal on the high-pressure discharge pipe.
    Fig 74: Installing New D-Ring Seal
    G03900056Courtesy of FORD MOTOR CO.
  77. Clean the cover mounting surface and apply sealant at the seams.
    Fig 75: Cleaning Cover Mounting Surface
    G03900057Courtesy of FORD MOTOR CO.
  78. Install the high-pressure pump cover.
    • Install the press-in-place gasket.
    • Install the high pressure pump cover.
    • Install the bolts.
    Fig 76: Installing High-Pressure Pump Cover
    G03900058Courtesy of FORD MOTOR CO.
  79. Install the turbocharger heat shield and bolts.
    Fig 77: Installing Turbocharger Heat Shield Bolts
    G03900059Courtesy of FORD MOTOR CO.
  80. Install the oil pump inlet strainer.
    Fig 78: Identifying Oil Pump Inlet Strainer
    G03887232Courtesy of FORD MOTOR CO.
    81. CAUTION: In the event of a catastrophic engine failure, always install the oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.
    Fig 79: Installing Oil Cooler Assembly
    G03900061Courtesy of FORD MOTOR CO.
  81. Install the oil cooler assembly.
    • Install the gasket.
    • Install the oil cooler assembly.
    • Install the bolts.
    82. NOTE: The old oil cooler cover bolts or new self-tapping bolts must be used to cut the threads in the new oil cooler cover.
    Fig 80: Installing Oil Filter Base
    G03900062Courtesy of FORD MOTOR CO.
  82. Install the oil filter base.
    • Install the gasket.
    • Install the oil filter base.
    • Install the bolts.
  83. Install the exhaust gas recirculation (EGR) cooler coolant supply port cover.
    • Install the gasket.
    • Install the EGR cooler coolant supply port cover.
    • Install the bolts.
    Fig 81: Installing EGR Cooler Coolant Supply Port Cover Bolts
    G03900063Courtesy of FORD MOTOR CO.
  84. Install new O-ring in the oil filter base.
    Fig 82: Identifying O-Ring Seals On Oil Filter Base
    G03887527Courtesy of FORD MOTOR CO.
  85. Install the serpentine belt idler and bolt.
    Fig 83: Installing Serpentine Belt Idler Bolt
    G03900065Courtesy of FORD MOTOR CO.
  86. Install the belt tensioner and bolts.
    Fig 84: Installing Belt Tensioner Bolts
    G03900066Courtesy of FORD MOTOR CO.
    87. NOTE: Install new sealing washers.
    Fig 85: Installing Left Cylinder Head Fuel Line
    G03900067Courtesy of FORD MOTOR CO.
  87. Install the left cylinder head fuel line.
    88. NOTE: Install a new O-ring on the thermostat.
    Fig 86: Installing Thermostat Housing Stud Bolts
    G03900068Courtesy of FORD MOTOR CO.
  88. Install the thermostat housing and stud bolts.
  89. Position the exhaust backpressure bracket assembly and install the retaining nuts.
    Fig 87: Installing Retaining Nuts
    G03900069Courtesy of FORD MOTOR CO.
  90. Tighten the exhaust backpressure tube at the exhaust manifold.
    Fig 88: Tightening Exhaust Backpressure Tube
    G03900070Courtesy of FORD MOTOR CO.
  91. Install the fuel lines and bracket bolt.
    Fig 89: Installing Fuel Lines Bracket Bolt
    G03900071Courtesy of FORD MOTOR CO.
    92. NOTE: Install a new O-ring on the oil indicator and tube. Apply clean engine oil to the O-ring.
    Fig 90: Installing Oil Level Indicator Tube Nut
    G03900072Courtesy of FORD MOTOR CO.
  92. Install the oil level indicator tube and nut.
  93. Install the special tool.
    Fig 91: Identifying Special Tool
    G03887258Courtesy of FORD MOTOR CO.
  94. Install the special tool.
    Fig 92: Installing Special Tool
    G03900074Courtesy of FORD MOTOR CO.
  95. Install the lifting crane and remove the engine from the engine stand.
    96. NOTE: Left side shown; right side similar.
    Fig 93: Installing Motor Mounts Bolts
    G03900075Courtesy of FORD MOTOR CO.
  96. Install the LH and RH motor mounts and bolts.
  97. Install the flexplate flywheel and the bolts.
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