Connecting Rod: Service and Repair
REMOVAL
1. Drain engine cooling system.
2. Remove upper intake manifold and lower intake manifold.
3. Remove cylinder heads.
4. Remove oil pan.
5. Remove oil pump screen cover and tube.
6. Before removing piston, inspect top of each cylinder bore. If a ridge has formed at the top of the cylinder bore, it must be removed before piston removal. Remove ridge as follows:
a. Turn crankshaft 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 303-016 (T64L-6011-EA) or equivalent. Never cut into ring travel area more than 0.8 mm (0.031 inch) when removing ridge.
7. 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 pistons, connecting rod bearings and connecting rod caps. Each component should be installed in its original position during assembly.
8. Remove connecting rod cap bolts, connecting rod cap and lower connecting rod bearing.
9. Turn crankshaft until piston to be removed is at the high point of its travel. If more than one piston is being removed, identify the pistons, connecting rods and connecting rod caps for cylinder position.
Remove the connecting rod cap and lower connecting rod bearing. Keep cap and lower connecting rod bearing together. Push the piston, connecting rod assembly and upper connecting rod bearing through the top of the cylinder bore. Use care to prevent damage to the bearing and cylinder bore surfaces. Keep upper connecting rod bearing and connecting rod together.
CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or possible damage to engine may occur.
NOTE: Connecting rod bolts are retained in the bolt hole with a light press fit. The connecting rod bolts have been torqued to yield at least twice and must be discarded. Use a hammer and punch to drive connecting rod bolts from connecting rod cap.
10. Using a new connecting rod bolt, attach cap and lower connecting rod bearing to connecting rod and upper bearing to prevent mixing parts and damaging the fractured joint face surfaces.
11. If piston is to be disassembled, refer to Pistons, Piston Pins and Rings, Disassembly and Assembly
12. Inspect cylinder bore. If new piston rings are to be installed on the piston a visible cross-hatch pattern should be obvious on the cylinder bore wall.
13. After honing, thoroughly clean cylinder bore using a detergent and water solution.
NOTE: If honing is required, remove glaze from cylinder wall using spring-loaded hone. Follow manufacturer's instructions when using this type of equipment.
INSTALLATION
1. Lubricate cylinder wall and piston with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
NOTE: Lightly oil all bolt threads before installation except those specifying special sealant with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
2. Install connecting rod guides on connecting rod bolt holes.
3. Install piston, connecting rod and upper connecting rod bearing using Piston Ring Compressor 303-D032 (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. The connecting rod and caps are numbered from 1 to 3 in the RH bank and from 4 to 6 in the LH bank, beginning at the front of the engine. Numbers on connecting rod and connecting rod cap must be on the same side when installed in cylinder bore. If a connecting rod is transposed from one cylinder block or cylinder to another, new connecting rod bearings should be fitted and connecting rod should be numbered to correspond with new cylinder number.
- Make sure raised bubble on side of piston dome faces front of engine.
4. Check connecting rod bearing clearance.
5. Lubricate bearing surfaces with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSR-M2G153-G
6. Make sure connecting rod is seated on crankshaft journal. Install connecting rod cap. Tighten retaining bolts in three steps:
a. Tighten to 20-25 Nm (15-18 ft. lbs.).
b. Tighten to 40-45 Nm (30-33 ft. lbs.).
c. Rotate an additional 90-120 degrees.
7. If necessary, check connecting rod side clearance.
8. Install oil pump screen cover and tube with a new oil pump inlet tube gasket. Tighten oil pump screen cover and tube retaining bolts to 20-30 Nm (15-22 ft. lbs.).
9. Tighten oil pump screen cover and tube support bracket retaining nut to 40-55 Nm (30-40 ft. lbs.).
10. Install oil pan.
11. Check piston deck clearance and bore clearance.
12. Install cylinder heads.
13. Install lower intake manifold and upper intake manifold.
14. Fill crankcase with the correct viscosity and amount of clean engine oil meeting Ford specification WSS-M2C153-G.
15. Fill and bleed engine cooling system.
16. Start engine and check for oil and coolant leaks.