Removal and Installation
REMOVAL
1. Drain engine cooling system.
2. Remove upper intake manifold (9424) and lower intake manifold.
3. Remove cylinder heads (6049).
4. Remove oil pan (6675).
5. Remove oil pump screen cover and tube (6622).
6. Before removing piston (6108), 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 (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 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.
NOTE: If more than one piston is being removed, identify the pistons, connecting rod bearings (6211) 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.
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.
9. Use a hammer and punch to drive connecting rod bolts from connecting rod cap.
10. 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 (6200) and connecting rod caps for cylinder position.
CAUTION:
Component Location/Orientation
The location and orientation of each precision machined component should be noted. When engine is assembled each component should be installed in its original position. These components include:
- Crankshaft main bearings and bearing caps.
- Connecting rod bearings and bearing caps.
- Pistons, piston rings and piston pins.
11. Remove the connecting rod cap and lower connecting rod bearing.
12. 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.
13. 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.
14. Disassemble pistons, piston pins and rings if required.
15. 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.
NOTE: If honing is required, remove glaze from cylinder wall using spring-loaded hone. Follow manufacturer's instructions when using this type of equipment.
16. After honing, thoroughly clean cylinder bore using a detergent and water solution.
INSTALLATION
NOTE: Lightly oil all bolt threads before installation except those specifying special sealant with clean engine oil meeting Ford specification WSS-M2C153-F.
1. Lubricate cylinder wall and piston with Engine Assembly Lubricant D9AZ-19579D or equivalent meeting Ford specification ESR-M99C80-A.
2. Install connecting rod guides on connecting rod bolt holes.
CAUTION: As piston is tapped into bore with a hammer handle, guide connecting rod onto crankshaft journal to avoid damage to bearing surfaces.
NOTE:
Component Locations
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 block (6010) or cylinder to another, new connecting rod bearings should be fitted and connecting rod should be numbered to correspond with new cylinder number.
Component Orientation
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. Make sure stamped arrow in piston dome faces front of engine.
3. Install piston, connecting rod and upper connecting rod bearing using Piston Ring Compressor D81L-6002-C or equivalent.
4. Check connecting rod bearing oil clearance.
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. Tighten retaining bolts in three steps:
Step 1 ... Tighten to 20-25 Nm (15-18 ft. lbs.).
Step 2 ... Tighten to 40-45 Nm (30-33 ft. lbs.).
Step 3 ... Rotate an additional 90-120°.
7. If necessary, check connecting rod side clearance.
8. Install oil pump screen cover and tube with a new oil pump inlet tube gasket (6626). 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 as shown.
12. Install cylinder heads.
13. Install lower intake manifold and upper intake manifold.
14. Fill crankcase with the correct viscosity and amount of engine oil.
15. Fill and bleed engine cooling system.
16. Start engine and check for oil and coolant leaks.