Removal and Installation
REMOVAL1. Drain engine cooling system.
2. Remove upper intake manifold (9424) and lower intake manifold as described.
3. Remove cylinder heads (6049) as described.
4. Remove oil pan (6675) as described.
5. Before removing piston (6108), inspect top of each cylinder bore. If a ridge has formed at the top of the cylinder, it must be removed before piston removal. Remove ridge as follows:
a. Turn crankshaft (6303) until piston to be removed is at bottom of cylinder bore.
b. Place a clean shop cloth over piston head to collect cuttings.
c. Remove ridge using Cylinder Ridge Reamer T64L-6011-EA. Never cut into ring travel area more than 0.8 mm (0.031 inch) when removing ridge.
6. Turn crankshaft until piston to be removed is at the low point of its travel.
- If more than one piston is being removed, identify the piston and connecting rod caps by numbering 1 through 3 from front to rear on RH bank and 4 through 6 from front to rear on LH bank. This will make sure each component is installed in its original position during assembly.
7. Remove connecting rod cap retaining nuts and cap.
8. Install ignition wire spark plug boots over connecting rod cap studs and push piston out through the top of the cylinder blocks (6010). Use care to prevent damage to bearing surfaces.
9. Install connecting rod cap and hold in position with cap retaining nuts.
10. If piston is to be disassembled, refer to disassembly and assembly.
11. Inspect cylinder bore. If new piston rings are to be installed on the piston, a cross-hatch pattern should be obvious on the cylinder bore wall.
If honing is required, remove glaze from cylinder bore wall using spring-loaded hone. Follow manufacturer's instructions when using this type of equipment.
After honing, thoroughly clean cylinder bore using a detergent and water solution.
INSTALLATION
1. Lubricate cylinder bore wall and piston with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
NOTE: Lightly oil all retaining bolt and stud threads before installation except those specifying special sealant.
2. Install ignition wire spark plug boots or suitable protection on connecting rod (6200).
3. Install piston with notch in piston dome facing the front of engine, using Piston Ring Compressor D81L-6002-C or equivalent.
CAUTION: As piston is tapped into bore with a hammer handle, guide connecting rod onto crankshaft journal to avoid damage to bearing surfaces.
NOTE: Install pistons in the same cylinders from which they were removed or to which they were fitted. If a connecting rod is transposed from one cylinder blocks or cylinder to another, new connecting rod bearings (6211) should be fitted and connecting rod should be numbered to correspond with new cylinder number.
4. Check connecting rod bearing clearances.
5. Lubricate bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
6. Make sure connecting rod is seated on crankshaft journal. Install connecting rod cap and tighten retaining bolts as follows:
- Tighten to 20-25 Nm (15-18 ft. lbs.).
- Tighten to 40-45 Nm (30-33 ft. lbs.).
- Rotate an additional 90-120 degrees.
7. If necessary, check connecting rod side clearance.
8. Install oil pump screen cover and tube (6622) with a new oil pump inlet tube gasket (6626) and tighten retainers as follows:
- Tighten oil pump screen cover and tube cylinder block bolts to 20-30 Nm (15-22 ft. lbs.).
- Tighten oil pump screen cover and tube support bracket retaining nut to 40-55 Nm (30-40 ft. lbs.).
9. Install oil pan.
10. Check piston deck Clearance and bore clearance as shown.
11. Install cylinder heads.
12. Install lower intake manifold and upper intake manifold.
13. Fill crankcase with the correct amount of clean engine oil meeting Ford specification WSS-M2C153-F.
14. Fill cooling system with the specified engine coolant.
15. Start engine and check for oil and coolant leaks.