Removal and Installation
REMOVAL1. Remove the cylinder head.
2. Remove the oil pan.
3. Remove the two bolts and the oil pump screen cover and tube. Discard the gasket.
4. Remove the four nuts and the oil pan baffle.
5. Inspect the top of each cylinder bore before removing the piston (6108). If a ridge has formed at the top of the cylinder, the ridge must be removed before the piston can be removed. Remove the ridge as follows:
A) Turn the crankshaft clockwise until the piston is at the bottom of its cylinder bore.
B) Place a clean shop cloth over the piston head to collect cuttings.
C) Use Cylinder Ridge Reamer T64L-6011-EA and remove the ridge. Never cut into the ring travel area more than 0.8 mm (1/32 in) when removing the ridge.
NOTE: If more than one piston is being removed, identify the pistons and connecting rod caps. Install each component in its original position during assembly.
6. Remove the (A) connecting rod nuts and the (B) connecting rod cap.
7. Install a short length of rubber tubing over the connecting rod bolts to avoid damage to journals and push the piston out through the top of the cylinder bore. Use care to prevent damage to the bearing surfaces.
8. Inspect the cylinder bore.
INSTALLATION
NOTE: Install the pistons in the same cylinders from which they were removed or to which they were fitted. The connecting rods and bearing caps must be on the same side when installed in the cylinder bore. If a connecting rod is transposed from one block or cylinder to another, new crankshaft main bearings (6333) should be fitted and the connecting rod should be numbered to correspond with the new cylinder number.
NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant.
1. Lubricate the cylinder wall and piston with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
2. Install a short length of rubber tubing over the connecting rod bolts to avoid damage to journals.
CAUTION: Guide the connecting rod (6200) onto the crankshaft journal as the piston is tapped into the bore to avoid damage to the connecting rod bearing surfaces.
NOTE: Install the piston with the lug on the piston dome facing the front of the engine.
3. Use (A) Piston Ring Compressor D81L-6002-C or equivalent to install the (B) piston.
4. Check the connecting rod bearing clearance.
NOTE: Do not cover the bearing squirt holes with lubricant.
5. Lubricate the connecting rod bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
6. Install the connecting rod cap.
^ Fit the connecting rod cap with a bearing.
^ Tighten the connecting rod nuts to 35-41 Nm (26-30 ft. lbs.). Back off the nuts two or three turns and retighten to 35-41 Nm (26-30 ft. lbs.).
7. Install the oil pan baffle and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
8. Install the oil pump screen cover and tube and new gasket. Tighten bolts to 8-11.5 Nm (71-102 inch lbs.).
9. Install the oil pan.
10. Check the piston squish height.
11. Install the cylinder head.