Removal and Installation
REMOVALNOTE: Pistons (6108), connecting rods (6200) and connecting rod bearings (6211) should be numbered to make sure they are assembled in their original positions.
1. Remove RH and LH cylinder heads (6049).
2. Remove and discard head gaskets (6051).
3. If cylinder heads are to be serviced, see cylinder head Disassembly and Reassembly.
4. Remove oil pan (6675) and oil pan gasket (6710).
5. Remove oil pump screen cover and tube (6622).
NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Cylinder Ridge Reamer T94L-6011-EA.
6. Turn crankshaft (6303) 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.
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 (6214) 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.
7. 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.
8. 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.
9. Clean and inspect piston, connecting rod, connecting rod bearings and cylinder block bores.
10. If required, disassemble piston from connecting rod.
11. If required, replace piston rings.
INSTALLATION
1. Coat piston bores, pistons and rings, crankshaft journal and bearing surfaces with clean engine oil meeting Ford specification WSS-M2C910-A1.
CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Push piston down until connecting rod bearing seats on crankshaft journal.
NOTE: Make sure piston ring gaps are rotated 30° apart. Notch on piston is to front of engine.
2. Turn crankshaft until the crankshaft throw is at bottom of stroke. Install correctly numbered piston and connecting rod assemblies with Piston Ring Compressor D81 L-6002-C or equivalent and Connecting Rod Guide T93P-6136-A.
NOTE: Due to the use of a cracked connecting rod joint face surface, the connecting rod cap must be properly aligned to the connecting rod. The connecting rod and connecting rod cap bearing tangs should be located on the same side of the connecting rod.
3. Alternately tighten connecting rod cap 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 bolts an additional 90-120°.
NOTE: After all connecting rod cap bolts are tightened to specification, rotate crankshaft to verify smooth operation.
4. Check connecting rod side clearance using Dial Indicator with Bracketry TOOL-4201-C or equivalent. Clearance should be 0.15-0.45 mm (0.006-0.0177 inch). If side clearance is greater than maximum service limit of 0.50 mm (0.020 inch), replace connecting rods and/or crankshaft.
NOTE: Install new O-ring; then start all bolts on oil pump (6600) and oil pump screen cover and tube before tightening.
5. Install oil pump screen cover and tube.
6. Install oil pan with new oil pan gasket.
7. If cylinder heads are to be serviced, see Disassembly and Reassembly.
CAUTION: Do not use sandpaper coarser than 600 grit.
NOTE: Clean cylinder head gasket surface with a toluene-based paint thinner or gasket remover.
8. If gasket material remains on head after cleaning, use a 600 grit sandpaper to remove remaining material.
NOTE: RH and LH head gaskets are not interchangeable.
9. Position new head gaskets on cylinder head.
CAUTION: Failure to position crankshaft as shown will cause damage to pistons and/or valve train components.
NOTE: With crankshaft in this position, no piston will be at top dead center (TDC.).
10. Rotate crankshaft to position as shown.
CAUTION: Use care when positioning cylinder heads. Damage to cylinder block (6010) and/or cylinder heads may result.
11. Install cylinder heads.