Ford — WSG-1068 ENGINE

A Ford service procedure — check it applies to your exact model before use.

Browse Ford generators & specs →

Procedure

1. Use the Valve Spring Compressor to compress the valve springs.
2. Remove the hydraulic lash adjusters.
3. Use the Valve Spring Compressor to compress the valve springs (6513), and remove the roller followers.
4. CAUTION: Do not remove the camshaft before removing the roller followers. CAUTION: Place the cylinder head on a cardboard or wood surface to prevent damage to the joint face. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. ! ! 02-95 WSG-1068 ENGINE
5. CAUTION: The caps must be marked for installation in their original location or damage to the engine may occur. Remove the bolts, the bearing caps and the camshaft.
6. Remove the valve stem seals (6571).
7. CAUTION: Keep the valves and the valve spring retainer keys (6518) in order so they can be installed in the same positions. NOTE: The 8-cylinder is shown. The 10-cylinder is similar. NOTE: Shown without camshaft for clarity. Remove the (A) valve spring retainer keys, the (B) valve spring retainers (6514), the (C) valve springs, and the valves. ! ! 02-96 WSG-1068 ENGINE Cylinder Head - Assembly
8. Lubricate the camshaft journals. • Use Super Premium SAE 5W30 Motor Oil D9AZ- 19579-A or equivalent meeting Ford specification WSS-M2C153-C.
9. Install the camshaft and the camshaft bearing caps in their original location and the bolts. • Lubricate and position the camshaft bearing caps. – Use Super Premium SAE 5W30 Motor Oil D9AZ-19579-A or equivalent meeting Ford specification WSS-M2C153-G.
10. CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage. • Use silicone gasket and sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE- M4G323-A6. NOTE: Sealant must be removed and area cleaned with solvent if above instructions are not followed. • Use metal surface cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE- M5B292-A. ! 02-97 WSG-1068 ENGINE
11. Tighten the bolts in the sequence shown.
12. Install the valves in the valve guides located in the cylinder block (6010). 02-98 WSG-1068 ENGINE
13. Install the valve spring and the valve spring retainer onto the valve.
14. Install the valve spring spacer between the valve spring coils to prevent valve stem seal damage.
15. Use the Valve Spring Compressor to compress the valve spring, and install the valve spring retainer keys.
16. Install the hydraulic lash adjusters. 02-99 WSG-1068 ENGINE
17. Remove the Valve Spring Spacer.
18. Install the roller followers. 02-100 WSG-1068 ENGINE Engine - Assembly Special Tool(s) Special Tool(s)
19. NOTE: Before assembling the cylinder block (6010), all seating surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. Lubricate and install the crankshaft upper main bearings into the cylinder block. • Use Super Premium SAE 5W30 Motor Oil D9AZ- 19579-A or equivalent meeting Ford specification WSS-M2C153-G. Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). 02-101 WSG-1068 ENGINE
20. Install the crankshaft (6303) into the cylinder block and onto the upper crankshaft main bearings (6333).
21. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer. Install the upper 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.
22. Push the crankshaft forward and install the front lower crankshaft thrust washer at the front of the No. 6 main boss.
23. Push the crankshaft rearward and install the rear lower crankshaft thrust washer (6334) at the back of the No. 6 main boss. 02-102 WSG-1068 ENGINE
24. 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 tap into place using a plastic or dead-blow hammer.
25. Install the ten dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.
26. Install new main cap bearing bolts. 02-103 WSG-1068 ENGINE
27. Tighten fasteners 13 through 24 in two stages in the sequence shown. • Stage 1: Tighten to 27-33 Nm (20-26 lb/ft). • Stage 2: Tighten an additional 85 degrees to 95 degrees.
28. Tighten fasteners 1 through 12 in two stages in the sequence shown. • Stage 1: Tighten to 37-43 Nm (22-32 lb/ft). • Stage 2: Tighten an additional 85 degrees to 95 degrees. 02-104 WSG-1068 ENGINE
29. Use the Connecting Rod Guide Tool and Piston Ring Compressor to install the piston and connecting rod assembly.
30. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod (6200). Once the connecting rod is seated on the crankshaft journal, remove the connecting rod guide tools.
31. 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 properly. Install the connecting rod bearings, position the connecting rod cap and loosely install the two new bolts. ! !
32. NOTE: Be sure to tighten the bolts in two stages. Tighten the connecting rod bolts in the sequence shown. • Stage 1: Tighten to 40-45 Nm (30-33 lb/ft). • Stage 2: Tighten an additional 90 degrees to 120 degrees.
33. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification. 02-105 WSG-1068 ENGINE
34. Install the oil filter adapter (6881).
35. Install the front engine support insulators (6038).
36. Install the lower crankshaft bearing supports and tighten fasteners in the sequence shown. 02-106 WSG-1068 ENGINE
37. Install the oil level indicator tube (6754).
38. Position the oil pump (6600) and install the bolts loosely. Tighten the bolts in the sequence shown.
39. Rotate the crankshaft to position the keyway at 12 o’clock. NOTE: After crankshaft has been positioned, do not turn the crankshaft until instructed to do so. 02-107 WSG-1068 ENGINE
40. Install the head gasket (6051) over the dowel pins.
41. Install the Camshaft Holding Tools.
42. Install the Lifting Handles.
43. Install the cylinder head (6049) on the head gasket and loosely install new bolts. • The LH is shown; the RH is similar.
44. NOTE: Be sure to tighten the new bolts in three stages. • Stage 1: Tighten to 37-43 Nm (27-32 lb/ft). • Stage 2: Tighten an additional 85 degrees to 95 degrees. • Stage 3: Tighten an additional 85 degrees to 95 degrees. 02-108 WSG-1068 ENGINE
45. Install the left and right exhaust manifold gaskets (9448) and exhaust manifolds (9430). Loosely install the nuts. Tighten the nuts in the sequence shown. 02-109 WSG-1068 ENGINE

Source: manual:WSG1068 Sec. 02-C Engine.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.