Section 637 (Engine 6.8L): Assembly: Engine: Assembly
WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
- Record the main bearing code found on the front of the engine block.
- Record the main bearing code found on the back of the crankshaft.
- Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings chart, 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 two intersect. This is the required bearing grade for the number one 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 four main bearings.
- If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings chart to determine the required bearing grade for each main bearing.
- Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
- Install the crankshaft into the cylinder block and onto the upper crankshaft main bearings.
- Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.
- Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.
- Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.
- Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
- Install the bolts.
- Install the 10 dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.
- Tighten fasteners 1 through 12 in two stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Tighten fasteners 13 through 24 in two stages, in the sequence shown.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Using the special tools, install the piston and connecting rod assembly.
- Once the connecting rod is seated on the crankshaft journal, remove the connecting rod guide tools.
- Install the connecting rod bearings, position the connecting rod cap and loosely install the two new bolts.
- Tighten the connecting rod bolts in the sequence shown.
- Stage 1: Tighten to 43 Nm (32 lb-ft).
- Stage 2: Tighten an additional 105 degrees.
- Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.
- Install the oil filter adapter.
- Install the front engine support insulators.
- Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
- Rotate the crankshaft to position the keyway at 12 o'clock.
- Install the head gasket over the dowel pins.
- Install the special tool.
- Install the cylinder head on the head gasket and loosely install the bolts.
- Remove the special tool.
- Tighten the bolts in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.
- Position the oil level indicator and install the nut attaching the oil level indicator tube to the front of the engine.
- Install the bolt attaching the oil level indicator tube to the rear of the engine.
- Install the left and right exhaust manifold gaskets and exhaust manifolds. Loosely install the nuts. Tighten the nuts in the sequence shown.
- Compress the tensioner plunger, using a vise.
- Install a retaining clip on the tensioner to hold the plunger in during installation.
- Remove the tensioner from the vise.
- If the copper links are not visible, mark two links on one end and one link on the other end to use as timing marks.
- Install the timing chain guides.
- Rotate the LH camshaft sprocket until the timing mark is approximately at 12 o'clock.
Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
- Position the crankshaft with the special tool.
- Remove the special tool.
- Install the crankshaft sprocket, making sure the flange faces forward.
- Install the lower end of the LH (inner) timing chain, aligning the timing marks.
- Position the timing chain on the LH camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned.
- Position the RH (outer) timing chain on the crankshaft sprocket.
- Position the RH timing chain on the camshaft sprocket. Make sure the two copper (marked) links align with the camshaft sprocket timing mark.
- As a post-check, verify timing mark alignment.
- Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
- Remove the retaining clip from the LH timing chain tensioner.
- Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
- Remove the retaining clip from the RH timing chain tensioner.
- Lubricate the balance shaft journals with clean engine oil.
- Using the index mark on the balance shaft, mark the corresponding teeth on the gear with chalk.
- Position the balance shaft on the journals.
- Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
- Install the bearing caps in their original locations and install the bolts. Tighten the bolts in the sequence shown.
- Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.
- Install the special tool between the valve spring coils to prevent valve stem seal damage.
- Install the camshaft roller followers.
- Install the special tool.
- Compress the valve spring.
- Install the camshaft roller followers in their original locations.
- Position the crankshaft sensor ring.
- Apply a bead of silicone gasket and sealant along the cylinder head-to-block surface and the oil pan-to-cylinder block surface as specified.
- Install a new engine front cover gasket onto the engine front cover, then position the engine front cover on the front cover to cylinder block dowel.
- Tighten the engine front cover fasteners in sequence in two stages.
- Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft).
- Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).
- Install the belt idler pulley and tighten the bolt.
- Position the oil pump screen and pickup tube.
- Install and tighten the spacer.
- Insert the oil pump screen pickup tube into the oil pump and position the support bracket over the spacer.
- Install and tighten the bolts.
- Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
- Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
- Install the oil pan. Tighten the bolts in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 20 Nm (15 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
- Install the oil drain plug.
- Install the water pump.
- Lubricate the new O-ring seal, using engine coolant, and install the O-ring seal onto the water pump.
- Position the water pump into the cylinder block.
- Install the water pump retaining bolts.
- Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
- Using the special tool, install the crankshaft front seal.
- Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
- Using the special tool, install the crankshaft pulley.
- Tighten the crankshaft pulley bolt in four stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
- Position the water pump pulley on the water pump and install the bolts.
- Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
- Position the valve covers.
- Tighten the bolts in the sequence shown.
- Install the engine control sensor wiring harness. Connect all of the harness routing clips and connector retainers.
- Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
- Connect the camshaft position (CMP) sensor electrical connector.
- Connect the RH radio frequency interference capacitor electrical connector.
- Connect the knock sensor electrical connector, if equipped.
- Connect the crankshaft position (CKP) sensor electrical connector.
- Connect the oil pressure switch electrical connector.
- Attach the special tool.
- Remove the engine from the engine stand.
- Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
- Install the retainer plate. Tighten the bolts in two stages.
- Stage 1: Tighten the retainer plate bolts to 10 Nm (89 lb-in), in the sequence shown.
- Stage 2: Tighten the oil pan bolts to 20 Nm (15 lb-ft), then tighten an additional 90 degrees.
- Using the special tools, install a new crankshaft rear seal.
- Using the special tools, install the crankshaft rear oil slinger.
- Install the flexplate.
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.
NOTE:
If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
NOTE:
If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
NOTE:
To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
NOTE:
If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
CAUTION:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
CAUTION:
The rod cap installation must keep the same orientation as marked during disassembly.
NOTE:
The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
NOTE:
Be sure to tighten the bolts in two stages.
NOTE:
Do not turn the crankshaft until instructed to do so.
NOTE:
LH shown; RH similar.
NOTE:
Be sure to tighten the bolts in three stages.
CAUTION:
Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTE:
There are 61 links in each timing chain.
CAUTION:
Unless otherwise instructed, at no time when the timing chain is removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
CAUTION:
Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston or valve damage can occur.
NOTE:
Make sure the upper half of the timing chain is below the tensioner guide dowel.
NOTE:
If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
NOTE:
Make sure the copper (marked) chain link and crankshaft sprocket timing mark are aligned.
NOTE:
The lower half of the timing chain must be positioned above the dowel.
NOTE:
If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
NOTE:
The LH timing chain tensioner arm has a bump near the dowel hole for identification.
NOTE:
Lubricate the camshaft roller followers, using clean engine oil.
NOTE:
If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE:
Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.
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 make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE:
If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE:
If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE:
Be sure to tighten the bolts in three stages.
CAUTION:
Do not rotate the water pump housing once the water pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
NOTE:
If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE:
If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 65: Applying Silicone Gasket And Sealant In Two Places Where Engine Front Cover Meets The Cylinder Head
CAUTION:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE:
If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE:
Lubricate the inner lip of the crankshaft rear seal with clean engine oil.