Disassembly and Assembly

DISASSEMBLY

NOTE: Mark the pistons (61O8) to ensure assembly with same connecting rod (6200) and installation in the same cylinders from which they were removed.

1. Remove pistons and connecting rods.
2. Remove piston rings from pistons.
3. Using Piston Pin Tool D81 L-6135-A or equivalent, press piston pin (6135) from piston and connecting rod.





ASSEMBLY
1. Clean and inspect pistons.
2. Clean and inspect connecting rod.
3. Apply a light coat of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to piston, piston pin and connecting rod.
4. Verify that all parts to be assembled are for same cylinder.

NOTE: Connecting rods may be installed into pistons with connecting rod identification mark in either direction.

5. Start piston pin in piston and connecting rod. This may require a very light tap with a mallet.
6. If required, using Piston Pin Remover and Replacer D81L-6135-A or equivalent, with guide pin, press piston pin through piston until piston pin bottoms on piston retainer ring.
7. After assembly, make sure connecting rod swings smoothly.
8. Install piston rings.
9. Install pistons with connecting rods.