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Lower Engine Block (View 2)

Fig 1: Exploded View Of Lower Block Components (View 2)
G07939960Courtesy of FORD MOTOR CO.
CALL OUTS FOR LOWER BLOCK COMPONENTS (VIEW 2)

Item Part Number Description
1 6161 Piston oil control spacer (4 required)
2 6150 Piston compression upper ring (4 required)
3 6152 Piston compression lower ring (4 required)
4 6159 Piston oil control upper segment ring (4 required)
5 6159 Piston oil control lower segment ring (4 required)
6 6140 Piston pin retainer (8 required)
7 6135 Piston pin (4 required)
8 6200 Connecting rod (4 required)
9 6211 Connecting rod upper bearing (4 required)
10 6110 Piston (4 required)
11 6211 Connecting rod lower bearing (4 required)
12 6210 Connecting rod cap (4 required)
13 6010 Cylinder block
14 6333 Cylinder block crankshaft main bearing (5 required)
15 6303 Crankshaft
16 6333 Crankshaft main bearing beam bearing (5 required)
17 6F098 Main bearing beam
18 6K360 Balance shaft assembly

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur. 

NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure. 

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to SPECIFICATIONS .

All vehicles 

    NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.
    NOTE: The front bulkhead does not have an oil squirter.
  1. Install the 4 oil squirters.
    • Tighten to 4 Nm (35 lb-in).
    2. Fig 2: Locating Oil Squirters
    G07939964Courtesy of FORD MOTOR CO.
  2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
    3. Fig 3: Measuring Crankshaft Main Bearing Journal Diameters In At Least 2 Directions
    G04480026Courtesy of FORD MOTOR CO.
  3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    4. Fig 4: Locating Main Bearing Beam
    G07939977Courtesy of FORD MOTOR CO.
  4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
    5. Fig 5: Identifying Main Bearing Beam Bolts Tightening Sequence
    G07939978Courtesy of FORD MOTOR CO.
  5. Measure each crankshaft block housing main bearing bore diameter.
    • Remove the bolts and the main bearing beam.
    • Discard the main bearing beam bolts.
    6. Fig 6: Identifying Crankshaft Block Main Bearing Bore Diameter
    G07939968Courtesy of FORD MOTOR CO.
  6. Using the chart, select the crankshaft main bearings.
    7. Fig 7: Crankshaft Main Bearings Chart
    G07939969Courtesy of FORD MOTOR CO.
  7. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Using the original connecting rod cap bolts, install the connecting caps and bolts.

    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
    • Remove the bolts and the connecting rod cap.
    • Stage 2: Tighten an additional 90 degrees.
      • Fig 8: Identifying Connecting Rod Large End Dimension
      G08733234Courtesy of FORD MOTOR CO.
  9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
    10. Fig 9: Identifying Crankshaft Connecting Rod Bearing Journal Diameters
    G07792034Courtesy of FORD MOTOR CO.
  10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    11. Fig 10: Connecting Rod Bearings Chart
    G07939972Courtesy of FORD MOTOR CO.
    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 reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
    NOTE: The center bulkhead is the thrust bearing.

  11. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.

    Fig 11: Locating Main Bearings
    G07939973Courtesy of FORD MOTOR CO.
    NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
  12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
    13. Fig 12: Locating Main Bearings
    G07939974Courtesy of FORD MOTOR CO.
  13. Lubricate journals on the crankshaft with clean engine oil.
  14. Position the crankshaft in the cylinder block.
    15. Fig 13: Locating Crankshaft
    G07939975Courtesy of FORD MOTOR CO.
  15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
    16. Fig 14: Locating Main Bearing Beam Side Fit Surfaces
    G07939976Courtesy of FORD MOTOR CO.
  16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
    17. Fig 15: Locating Main Bearing Beam
    G07939977Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
    NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

    Install and tighten the 10 new main bearing beam bolts.

    • Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
      • Fig 16: Identifying Main Bearing Beam Bolts Tightening Sequence
      G07939978Courtesy of FORD MOTOR CO.
  18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
    • Position the crankshaft to the rear of the cylinder block.
    • Zero the Dial Indicator Gauge with Holding Fixture.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
    • Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
      • Fig 17: Measuring Crankshaft End Play Using Dial Indicator Gauge With Holding Fixture
      G08717053Courtesy of FORD MOTOR CO.
  19. NOTICE: 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.
    NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
    NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

    Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.

    • When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
    • The position of the upper and lower compression ring gaps are not controlled for installation.
    20. Fig 18: Identifying Piston Ring Compressor And Connecting Rod Installer
    G07939980Courtesy of FORD MOTOR CO.
  20. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.
    NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

    Install the connecting rod caps and the new bolts.

    • Tighten the bolts in 2 stages.
    • Stage 1: Tighten to 29 Nm (21 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      • Fig 19: Identifying Connecting Rod Cap Bolts Tightening Sequence
      G07939981Courtesy of FORD MOTOR CO.
  21. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).
    22. Fig 20: Locating Crankshaft Timing Peg
    G07939986Courtesy of FORD MOTOR CO.
  22. NOTICE: Due to the precision interior construction of the balancer unit, it should not be disassembled. 
    NOTE: The original adjustment shims must be installed in their original position.
    NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.

    Install the adjustment shims in their original position on the seat faces of the balancer unit.

  23. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
    24. Fig 21: Locating Marking On Top Of Balancer Unit And Shafts
    G07781009Courtesy of FORD MOTOR CO.
  24. Install the balancer unit bolts.
    • Tighten in the sequence shown in 2 stages.
      • Stage 1: Tighten to 25 Nm (18 lb-ft).
      • Stage 2: Tighten to 50 Nm (37 lb-ft).
      • Fig 22: Identifying Balancer Unit Bolts Tightening Sequence
      G08019266Courtesy of FORD MOTOR CO.
  25. Remove the Crankshaft TDC Timing Peg.
    26. Fig 23: Locating Crankshaft TDC Timing Peg (303-507)
    G08019389Courtesy of FORD MOTOR CO.
  26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
  27. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
    • Remove the Crankshaft TDC Timing Peg.
      • Fig 24: Locating Crankshaft TDC Timing Peg (303-507)
      G08019389Courtesy of FORD MOTOR CO.
    28. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown
  28. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
    • Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
    • Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
    • If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. For additional information, refer to Lower Engine Block (View 2) .
      • Fig 25: Measuring Gear Backlash Using Dial Indicator Gauge
      G08019267Courtesy of FORD MOTOR CO.
    29. WARNING: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  29. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
    30. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
  30. Install the special tool.
    31. Fig 26: Locating Crankshaft TDC Timing Peg (303-507)
    G08019389Courtesy of FORD MOTOR CO.
  31. If removed, install the halfshaft support bracket and bolts.
    • Tighten to 40 Nm (30 lb-ft).
      • Fig 27: Removing Bolts And Halfshaft Support Bracket
      G03898029Courtesy of FORD MOTOR CO.
    32. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
  32. Install the oil pump assembly. Tighten the bolts in the sequence shown in 2 stages:
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
      • Fig 28: Identifying Tightening Sequence Of Oil Pump Assembly Bolts
      G03898057Courtesy of FORD MOTOR CO.
  33. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 Nm (89 lb-in).
      • Fig 29: Removing Bolts, Oil Pump Pickup Tube And Gasket
      G04319300Courtesy of FORD MOTOR CO.
  34. Using the special tool, install the crankshaft rear main oil seal.
    35. Fig 30: Installing Crankshaft Rear Main Oil Seal
    G04319324Courtesy of FORD MOTOR CO.
  35. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
    • To install, tighten to 10 Nm (89 lb-in).
      • Fig 31: Identifying Tightening Sequence Of Crankshaft Rear Oil Seal Bolts
      G03897722Courtesy of FORD MOTOR CO.
  36. NOTICE: 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 traces of sealant. 

    37. Clean and inspect all mating surfaces.

    NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  37. Apply a 2.5 mm (0.09 in.) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger tight.
    38. Fig 32: Applying Bead Of Silicone Gasket And Sealant To Oil Pan
    G04319326Courtesy of FORD MOTOR CO.
  38. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
    39. Fig 33: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block
    G04035567Courtesy of FORD MOTOR CO.
  39. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
      • Fig 34: Identifying Oil Pan Bolts Tightening Sequence
      G08019464Courtesy of FORD MOTOR CO.
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