Removal and Installation

REMOVAL
1. Drain the engine cooling system and the crankcase. Remove the upper intake manifolds (9424), lower intake manifold, cylinder heads (6049), oil pan (6675), oil pump screen cover and tube (6622) and oil pan baffle (6687).

CAUTION: Never cut into the ring travel area more than 0.8mm (0.125 inch) when removing ridges. Possible damage to engine may occur.

2. Remove any ridges and/or deposits from the upper end of the cylinder bores as follows:
a. Turn the crankshaft (6303) until the piston (6108) to be removed is at the bottom of its travel.
b. Place a cloth on the piston head to collect the cuttings.
c. Remove any ridge and/or deposits from the upper end of the cylinder bores.
d. Remove the cylinder ridge with Cylinder Ridge Reamer T64L-6011-EA.
3. Make sure all connecting rod caps are marked so that they can be installed in their original positions.
4. Turn the crankshaft until the connecting rod (6200) being removed is down.
5. 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.

6. Using Connecting Rod Guide Tool T94P-6136-AH installed into the connecting rod bolt holes, push the connecting rod and piston out the top of the cylinder block (6010) with the handle end of a hammer.

CAUTION:
^ Care should be taken not to damage the connecting rod and cap joint face surfaces or possible engine damage may occur.
^ 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.





7. Connecting rod bolts are retained in the bolt hole with a light press fit. The bolts have been torqued to yield at least twice and must be discarded. Using a hammer and punch, drive bolts from bolt holes.
8. Using a new connecting rod bolt, attach connecting rod cap and lower connecting rod bearing (6211) to connecting rod and upper connecting rod bearing to prevent mixing parts and damaging the connecting rod joint face surfaces.
9. If required, remove pistons from connecting rod.
10. If piston ring replacement is required, replace piston rings.

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.
3. Make sure the piston ring gaps are properly spaced around the circumference of the pistons.

CAUTION:
^ Install the pistons with the arrow in the piston head pointing toward the front of the engine or damage to engine will occur.
^ 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 transposed 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!

4. Install correctly numbered piston and connecting rod with Piston Ring Compressor D81L-6002-C or equivalent-and Connecting Rod Guide Tool T94P-6136-AH 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 or damage to the engine will occur.
^ 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 40 Nm (29 ft. lbs.). Rotate connecting rod bolts an additional 90-120°.
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 and the oil pump screen cover and tube.
12. Install the cylinder heads, timing chains, engine front cover (6019) and oil pan.
13. Install the upper intake manifold and lower intake manifold.
14. Replace oil bypass filter (6714).
15. Fill crankcase to proper level with Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification ESE-M2C153-E.
16. Fill and bleed the engine cooling system.
17. Operate the engine and check for oil and coolant leaks.