Facts About Generators
GeneratorsDirectoryCompareRepairEnginesControllersPartsManufacturersGuides
Search models or part #
Home›Repair guides›Ford›Engine - Assembly

Ford — Engine - Assembly

Repair & overhaul

From a Ford service manual — check it applies to your exact model before use.

Applies to: Ford WSG-1068 engine

Before you start

  • Timing chain procedures must be followed exactly or damage to valves and pistons (6108) will result.
  • Do not compress the ratchet assembly. This will damage the ratchet assembly.
  • Unless otherwise instructed, at no time when the timing chains (6268) are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
  • Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston or valve damage can occur.
  • The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured.
  • Do not scratch the cylinder walls or crankshaft journals with the connecting rod (6200).
  • The rod cap installation must keep the same orientation as marked during disassembly.
  • Do not rotate the water pump housing once the water pump (8501) has been positioned in the cylinder block. Damage to the O-ring seal will occur.
  • Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant.

Procedure

  1. Lubricate and install the crankshaft upper main bearings into the cylinder block.
  2. Install the crankshaft (6303) into the cylinder block and onto the upper crankshaft main bearings (6333).
  3. Push the crankshaft rearward and install the rear lower crankshaft thrust washer (6334) at the back of the No. 6 main boss.
  4. Push the crankshaft forward and install the front lower crankshaft thrust washer at the front of the No. 6 main boss.
  5. 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.
  6. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps and tap into place.
  7. Install new main cap bearing bolts.
  8. Install the ten dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.
  9. Use the Connecting Rod Guide Tool and Piston Ring Compressor to install the piston and connecting rod assembly.
  10. Install the connecting rod bearings, position the connecting rod cap and loosely install the two new bolts.
  11. Tighten the connecting rod bolts in the sequence shown; stage 1 40-45 Nm, stage 2 an additional 90-120 degrees.
  12. Install the oil filter adapter (6881). Install the front engine support insulators (6038).
  13. Install the lower crankshaft bearing supports and tighten fasteners in the sequence shown.
  14. Install the oil level indicator tube (6754). Position the oil pump (6600) and install the bolts loosely.
  15. Install the head gasket (6051) over the dowel pins; install Camshaft Holding Tools, Lifting Handles, the cylinder head (6049) and loosely install new bolts.

Tools required

  • Valve Spring Compressor Amazon
  • Connecting Rod Guide Tool Amazon
  • Piston Ring Compressor Amazon
  • Camshaft Holding Tools Amazon
  • Lifting Handles Amazon
  • Crankshaft Holding Tool Amazon
  • Crankshaft Seal Replacer/Aligner Amazon
  • Crankshaft Damper Replacer Amazon
  • Rear Crankshaft Seal Replacer Amazon
  • Rear Crankshaft Seal Adapter Amazon
  • Rear Crankshaft Slinger Replacer Amazon
  • Modular Lifting Bar Amazon

Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.

Specs & values

  • Connecting rod bolts: Stage 1 40-45 Nm (30-33 lb/ft), Stage 2 additional 90-120 FridayParts $377.99 degrees
  • Main bearing cap bolts fasteners 1-12: Stage 1 37-43 Nm, Stage 2 additional 85-95 FridayParts $13.80 degrees
  • Main bearing cap bolts fasteners 13-24: Stage 1 27-33 Nm, Stage 2 additional 85-95 FridayParts $13.80 degrees
  • Head bolts: Stage 1 37-43 Nm, Stage 2 additional 85-95 FridayParts $13.80 degrees, Stage 3 additional 85-95 FridayParts $13.80 degrees
  • Crankshaft pulley bolt: Stage 1 90 Nm, Stage 2 loosen 360 degrees, Stage 3 47-53 Nm, Stage 4 additional 85-90 FridayParts $45.52 degrees
  • Oil pan bolts: Stage 1 2 Nm, Stage 2 20 Nm, Stage 3 additional 60 degrees
  • Oil pan drain plug: 11-16 FridayParts $36.10 Nm (98-143 lb/in)
  • Timing chain tensioner bolts: 55-75 Nm (41-55 lb/ft)

Source: Ford service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

More Ford repair guides →