Lifter / Lash Adjuster: Service and Repair

NOTE: Before replacing a valve tappet for noisy operation, ensure the noise is not caused by improper valve-to-rocker arm clearance or by worn rocker arms or push rods.

Removal
1. Rotate crankshaft to zero degrees Top Dead Center (TDC) on the compression stroke.
2. Disconnect battery ground cable.
3. Drain engine cooling system.
4. Remove crankcase ventilation tube from valve cover and air cleaner outlet tube.
5. Remove aspirator hose from air cleaner outlet tube. Remove air cleaner outlet tube from throttle body and engine Air Cleaner (ACL).

WARNING: Cover the fuel pressure relief valve with a shop cloth to prevent accidental fuel spray into the eyes.

6. Carefully relieve fuel pressure at fuel pressure relief valve (Schrader valve).
7. Disconnect fuel lines.
8. Mark location and remove vacuum lines.
9. Disconnect fuel charging wiring from Intake Air Temperature (IAT) sensor and the engine control sensor wiring from the distributor (unleaded gasoline only). Disconnect fuel charging wiring from Camshaft Position (CMP) sensor on Flexible Fuel (FF) vehicles. On either model, disconnect fuel charging wiring from Throttle Position (TP) sensor, Idle Air Control (IAC) valve, Engine Coolant Temperature (ECT) sensor, ignition coil, water temperature indicator sender unit and Pressure Feedback Exhaust (PFE) or Delta Pressure Feedback Exhaust (DPFE) sensor electrical connectors.
10. Disconnect upper radiator hose from water hose connection. After loosening retaining clamp, use a twisting motion on upper radiator hose to loosen from water hose connection.
11. Remove brace from generator mounting bracket to throttle body stud bolt.
12. Remove EGR valve to exhaust manifold tube.
13. Remove throttle body.
14. Disconnect fuel charging wiring retainers from inboard valve cover stud bolts. Carefully disconnect fuel charging wiring from each fuel injector and remove fuel charging wiring from engine.
15. Disconnect heater water hoses.
16. Remove ignition wires from spark plugs. Remove wire harness retainers from valve cover bolts.
17. On non-Flexible Fuel vehicles, mark the distributor housing to cylinder block and note position of the distributor rotor. Remove distributor retaining bolt and washer. Remove distributor.
18. Remove ignition coil from rear of Left Hand cylinder head.
19. Remove valve covers.
20. Loosen cylinder No.3 intake valve rocker arm seat retaining bolt and rotate rocker arm off of push rod and away from top of valve stem. Remove push rod.

NOTE: Lower intake manifold may be removed with fuel injection supply manifold and fuel injectors in place as an assembly.

21. Remove lower intake manifold retaining bolts using a Torx (R) head socket. Before attempting to remove intake manifold, break seal between intake manifold and cylinder block.
- Wedge a large pry bar or similar tool between intake manifold and cylinder block.
- Pry upward on tool using area between water hose connection and transaxle as a leverage point.
22. Loosen rocker arm seat retaining bolt of valve tappet to be replaced enough to allow rocker arm to be lifted off the push rod and rotated to one side.

NOTE: Push rods should be installed in their original location and position during reassembly.

23. Remove push rods. If more than one is removed, identify each push rod's location.
24. Loosen two valve tappet guide plate and retainer bolts. Remove tappet guide plate and retainer from valve tappet valley.
25. Remove valve tappet guide plate from valve tappets by lifting straight up.

NOTE: If the valve tappets are stuck in the bore(s) due to excessive varnish or gum deposits, it may be necessary to use a claw type tool to aid removal. Rotate the valve tappet back and forth to loosen it from the deposits.

26. To remove, grasp valve tappet and pull in line with bore.

Installation

CAUTION: Aluminum components gouge easily which may cause gasket leaks. Always use care when scraping aluminum gasket surfaces.

NOTE: Lightly oil all retaining bolt and stud bolt threads before installation.

1. Clean mating gasket surfaces of lower intake manifold and cylinder head. Lay a clean cloth or shop cloth in the valve tappet valley to catch any gasket material. After scraping, carefully lift cloth from valve tappet valley to prevent any particles from entering oil drain holes or cylinder head. Use a suitable solvent to remove old silicone sealant.
2. Lubricate valve tappets and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification.
3. Install valve tappet into bore.
4. Aligning valve tappet flats, install valve tappet guide plate. Install valve tappet guide plate with word "UP" and/or button visible.
5. Install tappet guide plate and retainer over valve tappet guide plate. Retainer orientation is not important. Loosely install two retaining bolts. Tighten bolts to 10-14 N.m (8-10 lb-ft).

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification, to remove all residues that may interfere with the sealer's ability to adhere.

6. Apply a 6 mm (1/4 inch) drop of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications and to intersection of cylinder block and cylinder head at four corners.
7. Position intake manifold gasket onto cylinder heads. Align intake manifold gasket locking tabs to provisions on head gaskets.
8. Install front and rear intake manifold end seals. Secure with retaining features.
9. Carefully lower intake manifold into position aligning intake manifold bolt holes to those in cylinder head. Use care to prevent distributing silicone sealer which can cause sealing voids.
a. Install bolts No.1, 2, 3, and 4 and hand-tighten.
b. Install remaining bolts and tighten in a two step process.
- Tighten in numerical sequence to 20-30 N.m (15-22 lb-ft).
- Then tighten again in sequence to 26-32 N.m (19-24 lb-ft).

CAUTION: If a new distributor is installed, ALWAYS add the rest of the Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification to the engine oil by pouring it through the distributor hole onto the camshaft drive gear. Run engine at idle for five minutes prior to driving vehicle.

10. Coat entire distributor drive gear with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification.
- Install distributor and align to premarked location on cylinder block and distributor rotor position.
- Install retaining bolt and washer and hand tighten.

NOTE: Rocker arm seats must be fully seated into cylinder head and push rod must be fully seated in rocker arm and valve tappet sockets prior to final tightening.

11. Lubricate removed push rods and rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification. Move rocker arms into position with push rods and snug rocker arm seat retaining bolt. Rotate crankshaft to position camshaft lobes straight down and away from valve tappet.
- Tighten retaining bolt for rocker arm seats into cylinder head to 7-15 N.m (5-11 lb-ft).
- Final tighten rocker arm seat retaining bolt to 26-38 N.m (19-28 lb-ft) in any position.
12. Install valve covers.
13. Install fuel charging wiring to each fuel injector. Secure wire harness retainers to inboard valve cover stud bolts.
14. Install ignition coil to rear of Left Hand cylinder head. Tighten retaining bolts to 40-55 N.m (29-41 lb-ft).
15. Install distributor cap and ignition wires (unleaded gasoline only). Install ignition wire harness retainers to valve cover stud bolts and connect ignition wires to spark plugs and ignition coil.
16. Install throttle body. Install new intake manifold upper gasket.
17. Install EGR valve to exhaust manifold tube from intake manifold to EGR valve.
18. Install fuel lines.
19. Install fuel line safety retaining clips.
20. Install upper radiator hose and heater water hoses. Tighten retaining clamps securely.
21. Connect vacuum lines to premarked locations.
22. Connect electrical connections to IAT sensor and distributor (unleaded gasoline only). Connect electrical connections to IAC valve, ECT sensor, TPS, PFE or DPFE sensor, ignition coil and water temperature indicator sender unit.

NOTE: Engine coolant is corrosive to all engine bearing material.Replacing oil after removal of a coolant carrying component prevents damage.

23. Fill and bleed cooling system with specified coolant mixture.
24. Fill crankcase with the correct viscosity and amount of engine oil.
25. Install air cleaner outlet tube to throttle body and engine air cleaner.
26. Install crankcase ventilation tube to valve cover and air cleaner outlet tube. Install aspirator hose to air cleaner outlet tube.
27. Connect battery ground cable.
28. Start engine and check for coolant, oil, fuel and vacuum leaks.

NOTE: FF base initial engine timing is not adjustable.

29. Verify and if necessary correct base initial engine timing to 10 degrees BTDC. Tighten distributor retaining bolt to 24 N.m (18 lb-ft).
30. Install idle air control valve snowshield.