Section 244 (Engine - 6.2L V8): Assembly: Engine
For information on Ford Color Coded Illustrations, refer to OEM COLOR CODING
Special Tool(s) / General Equipment
| 205-142 (T80T-4000-J)Installer, Differential Bearing Cone | |
|---|---|
| 205-153 (T80T-4000-W)Handle | |
| 303-1250Seal Installer, Rear Main | TKIT-2006UFFLM | |
| 303-1507Brackets, Support | |
| 303-1508Installer, Front Crank Seal | |
| 303-335 (T88T-6701-A)Installer, Front Cover Oil Seal | TKIT-1988-FLM | TKIT-1988-F | |
| 303-F047Lifting Bracket, Engine | |
| Strap Wrench | |
| Floor Crane | |
| Mounting Stand | |
| Piston Ring Compressor | |
| Vise |
Materials
| Name | Specification |
|---|---|
| Motorcraft® High Performance Engine RTV SiliconeTA-357 | WSE-M4G323-A6 |
| Engine Oil - SAE 5W-30 - Synthetic Blend Motor OilXO-5W30-Q1SP | WSS-M2C946-B1 |
- Record the main bearing code and cylinder bore grades.
- Select-fit main bearings.
- Cylinder bore grades.
- Cylinder block serial number.
- Record the main bearing code found on the rear of the crankshaft.
- Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, 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 2 intersect. This is the required bearing grade for the No. 1 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 4 main bearings.
- If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
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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.
Install the piston oil cooler valves and the bolts.
Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 60 deg.
- Lubricate with clean engine oil and install the upper crankshaft main bearings.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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NOTE: Do not allow the crankshaft to come into contact with the piston oil cooler valves during assembly or engine damage may occur.
Lubricate with clean engine oil and install the crankshaft.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Lubricate with clean engine oil and push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Lubricate with clean engine oil and install the lower crankshaft main bearings and the lower thrust washer.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Lubricate with clean engine oil and install the main bearing caps and bolts on the cylinder block, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Push the crankshaft forward to seat the crankshaft thrust washer.
- Tighten the vertical main bearing cap fasteners in sequence shown.
Torque: Stage 1: Tighten bolts 1 through 10 to: 26 lb.ft (35 Nm) | Stage 2: Tighten bolts 1 thought 10 to: 37 lb.ft (50 Nm) | Stage 3: Tighten bolts 1 thought 10 an additional: 90 deg. | Stage 4: Tighten bolts 11 thought 20 to: 26 lb.ft (35 Nm) | Stage 5: Tighten bolts 11 thought 20 to: 48 lb.ft (65 Nm) | Stage 6: Tighten bolts 11 thought 20 an additional: 90 deg.
- Install the cross-mounted main bearing cap fasteners and tighten in sequence shown.
Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 26 lb.ft (35 Nm) | Stage 3: 60 deg.
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- Check the crankshaft end play clearance. Refer to: Specifications .
- Check the piston-to-cylinder bore clearance. Refer to: Specifications .
- Assemble the pistons and position the piston ring gaps. Refer to: Piston .
- Lubricate with clean engine oil and install the connecting rod bearings.
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NOTE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.NOTE: 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. Failure to follow this instruction may result in engine damage.NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
- Using a piston ring compressor, install the piston and connecting rod assembly.. Use the General Equipment: Piston Ring Compressor
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Repeat for each piston.
- Using a piston ring compressor, install the piston and connecting rod assembly.. Use the General Equipment: Piston Ring Compressor
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- Install the bearings, connecting rod caps and the new bolts finger tight.
- Repeat for each set of pistons.
- Tighten the connecting rod bolts in 3 stages, in the sequence shown.
Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 28 lb.ft (38 Nm) | Stage 3: 105 deg.
- Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
- Install the oil pump, upper bolts and the lower stud bolts.
Torque: Stage 1: Tighten all fasteners to: 18 lb.in (2 Nm) | Stage 2: Tighten the upper bolts to: 89 lb.in (10 Nm) | Stage 3: Tighten the lower stud bolts to: 177 lb.in (20 Nm) | Stage 4: Tighten the upper bolts an additional: 45 deg. | Stage 5: Tighten the lower stud bolts an additional: 60 deg.
- Lubricate with clean engine oil and install the oil pump screen and pickup tube O-ring seal.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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- Install the oil pump screen and pickup tube and the bolts.
Torque: 89 lb.in (10 Nm)
- Install the oil pump screen and pickup tube nut.
Torque: 18 lb.ft (24 Nm)
- Install the oil pump screen and pickup tube and the bolts.
- Install the new coolant pump O-ring seal and lubricate with clean engine coolant.
- Install the coolant pump and the bolts.
Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 45 deg.
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NOTE: Only rotate the engine in a clockwise direction.
- Install the crankshaft bolt.
- Using the crankshaft bolt, rotate the engine in a clockwise direction and position the crankshaft keyway at the 11 o'clock position.
- Remove the crankshaft bolt.
- Install the dowels on the LH bank of the cylinder block.
- Install a new LH cylinder head gasket.
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NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
Install the LH cylinder head and the new bolts and tighten in 10 stages.
Torque: Stage 1: Tighten bolts 1 through 10 to: 18 lb.ft (25 Nm) | Stage 2: Tighten bolts 1 through 10 to: 55 lb.ft (75 Nm) | Stage 3: Loosen: 180 deg. | Stage 4: Tighten bolts 1 through 10 to: 18 lb.ft (25 Nm) | Stage 5: Tighten bolts 1 through 10 to: 37 lb.ft (50 Nm) | Stage 6: Tighten bolt 11 to: 89 lb.in (10 Nm) | Stage 7: Tighten bolts 1 through 10 an additional: 90 deg. | Stage 8: Tighten bolts 1 through 10 an additional: 90 deg. | Stage 9: Tighten bolt 11 to: 177 lb.in (20 Nm) | Stage 10: Tighten bolt 11 an additional: 45 deg.
- Install the dowels on the RH bank of the cylinder block.
- Install a new RH cylinder head gasket.
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NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
Install the RH cylinder head and the new bolts and tighten in 7 stages.
Torque: Stage 1: Tighten bolts 1 through 10 to: 18 lb.ft (25 Nm) | Stage 2: Tighten bolts 1 through 10 to: 55 lb.ft (75 Nm) | Stage 3: Loosen: 180 deg. | Stage 4: Tighten bolts 1 through 10 to: 18 lb.ft (25 Nm) | Stage 5: Tighten bolts 1 through 10 to: 37 lb.ft (50 Nm) | Stage 6: Tighten bolts 1 through 10 an additional: 90 deg. | Stage 7: Tighten bolts 1 through 10 an additional: 90 deg.
- Install the crankshaft sprocket.
- Install the crankshaft pulley bolt and washer.
- Using a small pick, carefully push the LH tensioner rack pawl retainer away from the rack pawl and compress the tensioner plunger and rack using a vise.. Use the General Equipment: Vise
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- Install a retaining clip into the tensioner to hold the rack pawl and plunger in the seated position for tensioner installation.
- Remove the LH tensioner from the vise.
- If the copper links are not visible, mark the links on each end, and use as timing marks.
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NOTE: Verify the crankshaft keyway is at the 11 o'clock position.NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel and above the chain guide pin.
Install the LH timing chain.
- Align the colored link on the timing chain with the timing mark on the LH VCT assembly.
- Align the colored link on the timing chain with the timing mark on the crankshaft sprocket.
- Install the LH timing chain tensioner arm.
- Install the LH primary timing chain tensioner and bolts.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.
- Install the LH timing chain guide and the bolt.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.
- Remove the retaining clip from the LH timing chain tensioner.
- Using a small pick, carefully push the RH tensioner rack pawl retainer away from the rack pawl and compress the tensioner plunger and rack using a vise.. Use the General Equipment: Vise
-
- Install a retaining clip into the tensioner to hold the rack pawl and plunger in the seated position for tensioner installation.
- Remove the RH tensioner from the vise.
- If the copper links are not visible, mark the links on each end, and use as timing marks.
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NOTE: Verify the crankshaft keyway is at the 11 o'clock position.
Install the RH timing chain.
- Align the colored link on the timing chain with the timing mark on the crankshaft sprocket.
- Align the colored link on the timing chain with the timing mark on the RH VCT assembly.
- Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the bolts.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.
- Install the RH timing chain guide and bolt.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.
- Remove the retaining clip from the RH timing chain tensioner.
- As a post-check, verify correct alignment of all timing marks.
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- Using the crankshaft bolt, rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully opened.
- Lubricate the all RH camshaft lopes with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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NOTE: LH shown, RH similar.
Lubricate the LH and RH rocker arm shaft-to-valve tip and rocker arm-to-camshaft lobe contact area with clean engine oil prior to installation.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Lubricate the all LH camshaft lopes with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install the LH intake rocker arm shaft assembly and the bolts finger-tight and tighten the bolts sequence shown, in 3 stages.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 177 lb.in (20 Nm) | Stage 3: 60 deg.
- Using the crankshaft bolt, rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully opened.
- Install the LH exhaust rocker arm shaft assembly and the bolts finger-tight and tighten the bolts sequence shown, in 3 stages.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 177 lb.in (20 Nm) | Stage 3: 60 deg.
- Using the crankshaft bolt, rotate the engine clockwise until the No. 1 cylinder camshaft intake lobe is positioned so that the intake valve would be fully closed.
- Install the RH intake rocker arm shaft assembly and the bolts finger-tight and tighten the bolts sequence shown, in 3 stages.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 177 lb.in (20 Nm) | Stage 3: 60 deg.
- Using the crankshaft bolt, rotate the engine clockwise until the No. 1 cylinder camshaft exhaust lobe is positioned so that the exhaust valve would be fully closed.
- Install the RH exhaust rocker arm shaft assembly and the bolts finger-tight and tighten the bolts sequence shown, in 3 stages.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 177 lb.in (20 Nm) | Stage 3: 60 deg.
- Remove and discard the crankshaft pulley bolt and washer.
- Install the new gaskets on the engine front cover.
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NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned.NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.
Apply a 15 mm (0.59 in) drop of silicone sealant at the cylinder head-to-cylinder block and cylinder block-to-oil pan joint areas.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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- Install the engine front cover bolts and studs bolts finger-tight.
- Tighten the engine front cover bolts and studs bolts in sequence shown.
Torque: Tighten bolts 1 through 20 to: 89 lb.in (10 Nm) Tighten bolts 1 through 20 to: 177 lb.in (20 Nm) Tighten bolts 1 through 20 an additional: 30 deg.
- Install the RH VCT oil control solenoid and tighten the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 30 deg.
- Install the LH VCT oil control solenoid and tighten the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 30 deg.
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NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leaks.NOTE: The silicone must be applied on the groove along the retainer plate.
Apply a 3 mm (0.12 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer plate sealing surface.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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- Install the crankshaft rear seal retainer plate and the bolts finger-tight.
- Tighten the bolts in sequence shown.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 30 deg.
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NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned.
Apply an 8 mm (0.31 in) drop of Motorcraft® High Performance Engine RTV Silicone to the crankshaft rear seal retainer plate-to-cylinder block and engine front cover-to-cylinder block sealing surface.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install a new oil pan gasket.
- Install the oil pan and the bolts finger tight and tighten in 2 stages in the sequence shown.
Torque: Stage 1: 106 lb.in (12 Nm) | Stage 2: 40 deg.
- Install the accessory drive belt tensioner and the bolts.
Torque: 18 lb.ft (25 Nm)
- Install the accessory drive belt idler pulleys and the bolts.
Torque: 18 lb.ft (25 Nm)
- Install the coolant pump pulley and the bolts.
Torque: 18 lb.ft (25 Nm)
- Lubricate the engine front cover bore with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Using the special tools, install the new crankshaft front seal. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1508 Installer, Front Crank Seal.
- Lubricate the crankshaft front seal inner lip with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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NOTE: If the crankshaft pulley is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned.
Apply a bead of silicone gasket and sealant to the woodruff key slot.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1508 Installer, Front Crank Seal.
- Using the strap wrench, install a new crankshaft pulley bolt and tighten in 2 stages.. Use the General Equipment: Strap Wrench
Torque: Stage 1: 129 lb.ft (175 Nm) | Stage 2: 90 deg.
- If equipped, install the engine block heater.
Torque: 30 lb.ft (40 Nm)
- Install new oil filter adapter O-ring seals.
- Install the oil filter adapter and the bolts.
Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 60 deg.
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NOTE: Installation of new seals is only required if damaged seals were removed.
Using the special tools, install a new VCT oil control solenoid seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
- Install the oil fill cap.
- Install a new RH valve cover gasket.
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NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned.
Apply an 8 mm (0.31 in) drop of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install the RH valve cover and tighten the bolts.
Torque: 89 lb.in (10 Nm)
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NOTE: Installation of new seals is only required if damaged seals were removed.
Using the special tools, install a new VCT oil control solenoid seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
- Install a new LH valve cover gasket.
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NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned.
Apply an 8 mm (0.31 in) drop of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install the LH valve cover and tighten the bolts.
Torque: 89 lb.in (10 Nm)
- Lubricate oil level indicator tube O-ring seal and with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install the oil level indicator tube and the bolt.
Torque: 89 lb.in (10 Nm)
- Install the oil level indicator.
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- Install the new LH exhaust manifold studs.
Torque: 18 lb.ft (25 Nm)
- Install the new LH exhaust manifold gaskets.
- Install the new LH exhaust manifold studs.
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- Install the LH exhaust manifold and the new nuts finger-tight.
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NOTE: Torque sequence must be performed twice.
Tighten the exhaust manifold nuts in sequence shown.
Torque: Stage 1: 18 lb.ft (24 Nm) | Stage 2: 23 lb.ft (31 Nm)
- Install the LH exhaust manifold heat shield and the bolts.
Torque: 106 lb.in (12 Nm)
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- Install the RH new exhaust manifold studs.
Torque: 18 lb.ft (25 Nm)
- Install the new exhaust manifold gaskets.
- Install the RH new exhaust manifold studs.
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- Install the RH exhaust manifold and the new nuts finger-tight.
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NOTE: Torque sequence must be performed twice.
Tighten the exhaust manifold nuts in sequence shown.
Torque: Stage 1: 18 lb.ft (24 Nm) | Stage 2: 23 lb.ft (31 Nm)
- Install the RH exhaust manifold heat shield and the bolts.
Torque: 106 lb.in (12 Nm)
- Install the RH engine mount bracket and the bolts.
Torque: Stage 1: 22 lb.ft (30 Nm) | Stage 2: 60 deg.
- Install the LH engine mount bracket and the bolts.
Torque: Stage 1: 22 lb.ft (30 Nm) | Stage 2: 60 deg.
- Install the thermostat.
- Install and lubricate the thermostat housing O-ring seal.
- Install the thermostat housing and upper radiator hose assembly and the bolts.
Torque: 89 lb.in (10 Nm)
- Install the KS and the bolts.
Torque: 177 lb.in (20 Nm)
- Connect the RH spark plug wires to the lower spark plugs and attach the retainers to the valve cover.
- Connect the LH spark plug wires to the lower spark plugs and attach the retainers to the valve cover.
- Install the radio ignition interference capacitors and the nuts.
Torque: 18 lb.ft (25 Nm)
- Install the special tools and the bolts. Install Special Service Tool: 303-1507 Brackets, Support., 303-F047 Lifting Bracket, Engine.
- Using the floor crane, remove the engine from the mounting stand.. Use the General Equipment: Floor Crane. Use the General Equipment: Mounting Stand
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NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.
Using the special tools, install the new crankshaft rear seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1250 Seal Installer, Rear Main.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install he CKP sensor and the bolt.
Torque: 89 lb.in (10 Nm)
- Inspect the ignition pulse ring for damage. If the ignition pulse ring has been dropped or has any visual damage, it must be replaced.
- With the inset hole on the crankshaft ignition pulse ring aligned with the inset hole on the crankshaft flange, install the crankshaft ignition pulse ring.
- Install the engine-to-transmission spacer plate.
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NOTE: Flexplate shown, flywheel similar.
- Install the flexplate and the new bolts finger-tight.
- Tighten the bolts in sequence shown in 6 stages.
Torque: Stage 1: Tighten fasteners 1 through 4 in sequence to: 177 lb.in (20 Nm) | Stage 2: Tighten fasteners 1 through 4 in sequence to: 26 lb.ft (35 Nm) | Stage 3: Tighten fasteners 1 through 4 in sequence an additional: 60 deg. | Stage 4: Tighten fasteners 5 through 8 in sequence to: 177 lb.in (20 Nm) | Stage 5: Tighten fasteners 5 through 8 in sequence to: 26 lb.ft (35 Nm) | Stage 6: Tighten fasteners 5 through 8 in sequence an additional: 60 deg.