Removal and Installation

REMOVAL
1. Drain the engine cooling system and the crankcase (engine oil). Remove the intake manifold (9424), cylinder head (6049), oil pan (6675), oil pump screen cover and tube (6622) and oil pan baffle (6687).
2. If removed, reinstall generator mounting bracket (10153) to cylinder block (6010).
3. Reinstall RH engine lifting eye (17A084) to generator mounting bracket. Tighten retainers securely.
4. Raise engine and support with Three Bar Engine Support D88L-6000-A or equivalent.
5. Remove any ridges and/or deposits from the upper end of the cylinder bores as follows.

CAUTION: Never cut into the ring travel area when removing ridges. Possible damage to engine may occur.

6. Turn the crankshaft (6303) until the piston (6108) to be removed is at the bottom of its travel. Place a cloth on the piston head to collect the cuttings. Remove any ridge and/or deposits from the upper end of the cylinder bores. Remove the cylinder ridge with Rotunda Cylinder Ridge Reamer 014-00292 or equivalent.
7. Make sure all connecting rod caps are marked so that they can be installed in their original positions.
8. Turn the crankshaft until the connecting rod (6200) being removed is down.
9. Remove the connecting rod bolts and cap.

CAUTION: Avoid damage to the crankshaft journal or the cylinder wall when removing the piston and connecting rod.

10. Push the connecting rod and piston assembly out the top of the cylinder block with the handle end of a hammer.
11. Remove the connecting rod bearings (6211) from the connecting rod and cap.
12. Install the cap on the connecting rod from which it was removed.

INSTALLATION
1. If new piston rings are to be installed and no visible cross-hatch marks remain on the cylinder wall, remove the cylinder wall glaze using a spring-type tool. Follow the instructions of the tool manufacturer. After honing, clean the cylinder walls with a detergent and water solution.
2. Lubricate the piston rings, pistons and cylinder walls with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Be sure to install the pistons in the same cylinders from which they were removed or to which they were fitted. The connecting rods and bearing caps should be numbered on the same side, beginning at the front of the engine. The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. If a connecting rod is ever transferred from one cylinder block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod and cap should be numbered to correspond with the new cylinder number.
3. Make sure the piston ring gaps are properly spaced around the circumference of the pistons. Follow proper procedures.

CAUTION: Install the pistons with the arrow in the piston head pointing toward the front of the engine.

4. install correctly numbered piston and connecting rod with Piston Ring Compressor D81L-6002-C or equivalent and Connecting Rod Guides T93P-6136-A and push the piston in with a hammer handle until it is slightly below the top of the cylinder block. Be sure to guide the connecting rods to avoid damaging the crankshaft journals.
5. Check the clearance of each connecting rod bearing.
6. After the bearings have been fitted, apply a light coating of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to the journals and connecting rod bearings.
7. Turn the crankshaft throw to the bottom of its stroke. Push the piston all the way down until the connecting rod bearings seat on the crankshaft journal.

CAUTION:
^ It is imperative that the connecting rod cap be properly aligned to the connecting rod. The connecting rod and connecting rod cap bearing tangs must be located on same side of connecting rod.
^ Connecting rod bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused. Failure to replace connecting rod bolts may cause possible damage to engine.

8. Install the connecting rod cap. Tighten the new torque-to-yield bolts alternately in several passes to 35 Nm (26 ft. lbs.). Rotate connecting rod bolts an additional 85-95°.
9. After the pistons and connecting rods have been installed, check the side clearance between the connecting rods on each crankshaft journal.
10. Clean the oil pump screen cover and tube, oil pan baffle and the oil pan and cylinder block gasket surfaces.
11. Install the oil pan baffle, the oil pump screen cover and tube and the oil pan.
12. Support the front of the engine with a wood block between the crankshaft pulley and front sub-frame (5C145).
13. Remove Three Bar Engine Support D88L-6000-A or equivalent.
14. Remove RH engine lifting eye from generator mounting bracket.
15. Install the cylinder head and camshaft timing belt.
16. Install the intake manifold.
17. Replace oil bypass filter (6714).
18. Fill and bleed the engine cooling system.
19. Operate the engine and check for oil and coolant leaks.