Removal & Installation

CAUTION
The connecting rod bearings are a selective fit to provide the necessary clearance. Measure clearance and select the proper connecting rod bearing.

REMOVAL
1. Disconnect battery ground cable. Refer to Starting and Charging.
2. Drain engine cooling system.
3. Drain crankcase.
4. Remove spark plugs. Refer to Powertrain Management.
5. Raise and support vehicle.
6. Remove oil pan.
7. Remove oil pump if required.
8. Turn crankshaft until connecting rod from which the connecting rod bearings are to be removed is at lowest point of travel.
9. Loosen retaining nuts and remove from connecting rod cap. Place retaining nuts so that they may be reinstalled on the same connecting rod bolt.

NOTE: Use extreme care to not scratch crankshaft journal.

10. Tap connecting rod cap with a plastic mallet to separate from connecting rod. Carefully remove connecting rod cap from crankshaft. If lower connecting rod bearing remained on crankshaft, carefully grasp both sides and remove (oil acts as an adhesive between two precision fitted components).

NOTE: Use extreme care to not scratch crankshaft journal.

11. Install protective rubber caps onto connecting rod bolts to protect crankshaft journal from bolt threads. Rubber fuel line can also be used.
12. Remove upper connecting rod bearing. Push piston up enough to grasp connecting rod bearing. If connecting rod bearing remained on crankshaft, allow connecting rod bearing to remain in contact with crankshaft journal and carefully rotate to bottom side of journal. Using care, remove connecting rod bearing from crankshaft.
13. Inspect connecting rod bearings, crankshaft journal and connecting rod bearing surfaces for damage or wear.

INSTALLATION

CAUTION: Contaminants allowed to remain on the connecting rod cap or connecting rod bearing can distort the connecting rod bearing or damage the crankshaft journals which may result in engine failure.

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

1. Thoroughly clean connecting rod bearings, connecting rod cap and connecting rod.
2. Lubricate crankshaft journal with Engine assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Make sure the entire journal is well lubricated.
3. Install upper connecting rod bearing in the connecting rod and pull the connecting rod down until it seats on the crankshaft. When installing connecting rod bearing, make sure tab on connecting rod bearing engages slot in connecting rod and that connecting rod bearing is fully seated in connecting rod.
4. Install lower connecting rod bearing in connecting rod cap and lubricate bearing surface with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
5. Remove protective rubber caps from connecting rod bolts.
6. Install connecting rod cap and retaining nuts. Install caps with code letters on same side as code letters on connecting rods. Tighten nuts to 31-39 Nm (23-28 ft. lbs.).
7. Install oil pump if removed. Align oil pump intermediate shaft with distributor shaft, then align oil pump with dowels and install retaining bolt. Tighten to 40-55 Nm (30-40 ft. lbs.).
8. Inspect and clean oil pump screen cover and tube.
9. Install oil pan.
10. Lower vehicle.
11. Install spark plugs. Refer to Powertrain Management.
12. Fill crankcase with the correct viscosity and amount of engine oil.
13. Fill and bleed engine cooling system.
14. Connect battery ground cable.
15. Disconnect engine control sensor wiring from ignition coil. Crank engine for 15 seconds to re-establish oil to oil pump and bearing surfaces.
16. Connect ignition coil.
17. Start engine and check for coolant, oil and exhaust leaks.