Disassembly And Assembly
DISASSEMBLY1. Remove connecting rod bearings from connecting rods and caps.
2. Remove piston rings using a suitable piston ring expander.
3. Mark connecting rod cap to make sure assembly with the same piston and installation in the same cylinders from which they were removed.
4. Using an Arbor Press and Piston Pin Remover/Replacer 303-S024 (T68P-6135-A), press the piston pin from the piston and connecting rod.
NOTE: Mark piston to match cylinder number. Matching letters are stamped in the sides of corresponding connecting rod and cap.
ASSEMBLY
NOTE: Check the fit of a new piston in the cylinder bore before assembling the piston and piston pin to the connecting rod.
The piston pin bore of a connecting rod and the diameter of the piston pin must be within specification.
1. Apply a light coat of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to all components.
Piston & Rod Assembly:
2. Assemble the piston to the connecting rod, putting the notch in the piston dome and the connecting rod on the same side.
On V-6 engines with one connecting rod per piston pin, both sides of connecting rod have larger chamfers.
3. Start the piston pin in the piston and connecting rod. (This may require a very light tap with a mallet.) Using an Arbor Press and Piston Pin Remover/Replacer 303-S024 (T68P-6135-A), press the piston pin through the piston until the piston pin is centered in the piston.
4. Check the end gap of all piston rings. It must be within specification. Follow the instructions contained on the piston ring package and install the piston rings.
5. Check the piston ring side clearance of the compression rings with Feeler Gauge 303-D027 (D81L-4201-A) or equivalent by inserting it between the piston ring and its lower land. The gauge should slide freely around the entire ring circumference without binding. Any wear that occurs will form a step at the inner portion of the lower land. If the lower lands have high steps, the piston should be replaced.
6. Make sure the connecting rod bearings and the bearing bore in the connecting rod and cap are clean. Foreign material under the connecting rod bearings will distort the connecting rod bearing and cause a failure. Install the connecting rod bearings in the connecting rod and cap with the tangs fitting in the slots provided.