Engine - 6.8L: Assembly: Engine: Assembly

Record the main bearing code found on the front of the engine block.

Fig 1: Measuring Clearance Using Feeler Gauge
Courtesy of FORD MOTOR CO.
Record the main bearing code found on the back of the crankshaft.

Fig 2: Identifying Main Bearing Code Found On Back Of Crankshaft
Courtesy of FORD MOTOR CO.
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.
Fig 3: Crankshaft Specification Chart (Standard Size)
Courtesy of FORD MOTOR CO.
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.

Fig 4: Crankshaft Specification Chart (Oversize)
Courtesy 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.

Fig 5: Installing Crankshaft Upper Main Bearings Into Cylinder Block

Courtesy of FORD MOTOR CO.

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.

Fig 6: Installing Crankshaft Into Cylinder Block
Courtesy of FORD MOTOR CO.
Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.

Fig 7: Installing Rear Upper Crankshaft Thrust Washer
Courtesy of FORD MOTOR CO.
Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.

Fig 8: Installing Front Upper Crankshaft Thrust Washer
Courtesy of FORD MOTOR CO.

NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

Fig 9: Installing Lower Crankshaft Thrust Washer

Courtesy of FORD MOTOR CO.

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 tap into place using a plastic or dead-blow hammer.

Fig 10: Taping Main Bearing Caps On Cylinder Block Using Plastic Or Dead-Blow Hammer
Courtesy of FORD MOTOR CO.
Install the bolts.

Fig 11: Installing Bolts
Courtesy of FORD MOTOR CO.
Install the 10 dowel pins so that the flat sides face the crankshaft. Install the crossmounted bolts.

Fig 12: Installing Dowel Pins So That Flat Sides Face Crankshaft
Courtesy of FORD MOTOR CO.
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.
Fig 13: Identifying Fasteners Tightening Sequence (1 To 12)
Courtesy of FORD MOTOR CO.
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.
Fig 14: Identifying Fasteners Tightening Sequence (13 To 24)
Courtesy of FORD MOTOR CO.
Using the special tools, install the piston and connecting rod assembly.

Fig 15: Installing Piston And Connecting Rod Assembly Using Special Tools
Courtesy of FORD MOTOR CO.

CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Once the connecting rod is seated on the crankshaft journal, remove the connecting rod guide tools.

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.

Install the connecting rod bearings, position the connecting rod cap and loosely install the two new bolts.

NOTE: Be sure to tighten the bolts in two stages.

Fig 16: Identifying Tightening Sequence Of Connecting Rod Bolts

Courtesy of FORD MOTOR CO.

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.

Fig 17: Installing Oil Filter Adapter
Courtesy of FORD MOTOR CO.
Install the front engine support insulators.
Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.

Fig 18: Positioning Oil Pump And Installing Bolts
Courtesy of FORD MOTOR CO.
Rotate the crankshaft to position the keyway at 12 o'clock.

Fig 19: Rotating Crankshaft To Position Keyway At 12 O'Clock
Courtesy of FORD MOTOR CO.

NOTE: Do not turn the crankshaft until instructed to do so.

Fig 20: Installing Head Gasket Over Dowel Pins

Courtesy of FORD MOTOR CO.

Install the head gasket over the dowel pins.
Install the special tool.

Fig 21: Installing Special Tool
Courtesy of FORD MOTOR CO.

NOTE: LH shown; RH similar.

Fig 22: Installing Cylinder Head And Bolts

Courtesy of FORD MOTOR CO.

Install the cylinder head on the head gasket and loosely install the bolts.
Remove the special tool.

Fig 23: Removing Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Be sure to tighten the bolts in three stages.

Fig 24: Identifying Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

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.
Install the oil level indicator tube.

Fig 25: Installing Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
Install the left and right exhaust manifold gaskets and exhaust manifolds. Loosely install the nuts. Tighten the nuts in the sequence shown.

Fig 26: Installing Left And Right Exhaust Manifold
Courtesy of FORD MOTOR CO.

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

Fig 27: Compressing Tensioner Plunger, Using Vise

Courtesy of FORD MOTOR CO.

Compress the tensioner plunger, using a vise.
Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 28: Installing Retaining Clip On Tensioner To Hold Plunger
Courtesy of FORD MOTOR CO.
Remove the tensioner from the vise.

NOTE: There are 61 links in each timing chain.

Fig 29: Marking Two Links On One End And One Link On Other End To Use As Timing Marks

Courtesy of FORD MOTOR CO.

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.

Fig 30: Installing Timing Chain Guides
Courtesy of FORD MOTOR CO.
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.

Fig 31: Rotating LH Camshaft Sprocket Until Timing Mark Is Approximately At 12 O'Clock
Courtesy of FORD MOTOR CO.

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.

Fig 32: Positioning Crankshaft With Special Tool

Courtesy of FORD MOTOR CO.

Position the crankshaft with the special tool.
Remove the special tool.
Install the crankshaft sprocket making sure the flange faces forward.

Fig 33: Installing Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the lower end of the LH (inner) timing chain, aligning the timing marks.

Fig 34: Aligning Timing Marks
Courtesy of FORD MOTOR CO.

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.

Fig 35: Aligning LH Camshaft Sprocket With Two Copper (Marked) Chain Links And Camshaft Sprocket Timing Mark

Courtesy of FORD MOTOR CO.

Position the timing chain on the LH camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned.

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.

Fig 36: Positioning RH (Outer) Timing Chain On Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Position the RH (outer) timing chain on the crankshaft sprocket.

NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

Fig 37: Aligning Two Copper (Marked) Links With Camshaft Sprocket Timing Mark

Courtesy of FORD MOTOR CO.

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.

Fig 38: Inspecting Timing Mark Alignment
Courtesy of FORD MOTOR CO.

NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Fig 39: Installing LH Timing Chain Tensioner

Courtesy of FORD MOTOR CO.

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.

Fig 40: Removing Retaining Clip From LH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.

Fig 41: Installing RH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Remove the retaining clip from the RH timing chain tensioner.

Fig 42: Removing Retaining Clip From RH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
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.

Fig 43: Balancing Shaft Using Index Mark On
Courtesy of FORD MOTOR CO.
Position the balance shaft on the journals.

Fig 44: Positioning Balance Shaft On Journals
Courtesy of FORD MOTOR CO.
Align the chalk mark on the balance shaft with the camshaft timing mark as shown.

Fig 45: Aligning Chalk Mark On Balance Shaft With Camshaft Timing Mark
Courtesy of FORD MOTOR CO.
Install the bearing caps in their original locations and install the bolts. Tighten the bolts in the sequence shown.

Fig 46: Installing Bearing Caps And Bolts
Courtesy of FORD MOTOR CO.
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.

Fig 47: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the camshaft roller followers using clean engine oil.

Fig 48: Installing Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Install the camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.
Remove the special tool.

Fig 49: Removing Special Tool
Courtesy of FORD MOTOR CO.
Position the crankshaft sensor ring.

Fig 50: Positioning Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.

NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Fig 51: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Block Surface

Courtesy of FORD MOTOR CO.

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.

Fig 52: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.
Loosely install the fasteners.

Fig 53: Identifying Fasteners Installing Sequence
Courtesy of FORD MOTOR CO.
Tighten the fasteners in two stages. Refer to the preceding illustration.
- 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.

Fig 54: Installing Belt Idler Pulley And Tightening Bolt
Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.

Fig 55: Installing Oil Pump Screen And Pickup Tube

Courtesy of FORD MOTOR CO.

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.

Apply a bead of silicone gasket and sealant where the rear crankshaft seal retainer plate and the front cover meets the cylinder block.

NOTE: Be sure to tighten the bolts in three stages.

Fig 56: Identifying Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

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.

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.

Fig 57: Installing Water Pump And Retaining Bolts

Courtesy of FORD MOTOR CO.

Install the water pump.
1. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the water pump.
2. Position the water pump into the cylinder block.
3. Install the water pump retaining bolts.
Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.

Fig 58: Positioning Front Oil Seal
Courtesy of FORD MOTOR CO.
Using the special tool, install the crankshaft front seal into the engine front cover.

Fig 59: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool
Courtesy of FORD MOTOR CO.

Fig 60: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
Using the special tool, install the crankshaft pulley.

Fig 61: Installing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.
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.
Fig 62: Installing And Tightening Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Position the water pump pulley on the water pump and install the bolts.

Fig 63: Positioning Water Pump Pulley On Water Pump And Installing Bolts
Courtesy of FORD MOTOR CO.

Fig 64: Applying Silicone Gasket And Sealant In Two Places Where Engine Front Cover Meets Cylinder Head

Courtesy of FORD MOTOR CO.

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.

Fig 65: Identifying Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the engine control wire harness.
Attach the Modular Engine Lift Bracket.
Remove the engine from the engine stand.

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.

Clean and inspect the mating surfaces of the cylinder block and the retainer plate.

NOTE: If not secured within 4 minutes, 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.

Fig 66: Applying Bead Of Silicone Around Rear Oil Seal Retainer Sealing Surface

Courtesy of FORD MOTOR CO.

Apply a bead of silicone 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.
Fig 67: Installing Retainer Plate
Courtesy of FORD MOTOR CO.
Use the two Crankshaft Rear Oil Seal Installers to install the crankshaft rear oil seal.

Fig 68: Installing Crankshaft Rear Oil Seal Using Crankshaft Rear Oil Seal Installers
Courtesy of FORD MOTOR CO.
Using the two Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear oil slinger.
Install the flexplate.

Fig 69: Installing Flexplate
Courtesy of FORD MOTOR CO.