Hydraulic Valve Tappet

NOTE: Before replacing a valve tappet (6500) for noisy operation, make sure the noise is not caused by improper valve-to-rocker arm clearance or by worn rocker arms (6564) or push rods (6565) .

Removal

1. Disconnect ignition wires at the spark plugs (12405) . To avoid damaging ignition wires use Spark Plug Wire Remover T74P-6666-A.

2. Remove ignition wire routing clips from studs on the valve cover retaining bolts. Lay ignition wires with routing clips toward front of engine.

3. Remove upper intake manifold (9424) as outlined.

4. Remove valve covers (6582) as outlined.

5. Remove lower intake manifold as outlined.

6. Sufficiently loosen each rocker arm fulcrum retaining bolt to allow rocker arm to be lifted off push rod and rotated to one side.

7. Remove push rods. The location of each push rod should be identified. When engine is assembled, each push rod should be installed in its original position.

8. Remove four bolts holding two tappet guide plates and retainers (6K564) in place (bolts are held captive in retainers). Remove six valve tappet guide plates (6K512) from adjacent valve tappets .

9. Remove valve tappets using a magnet. The location of each valve tappet should be identified. When engine is assembled, each valve tappet should be installed in its original position.

   If valve tappets are stuck in bores due to excessive varnish or gum deposits, it may be necessary to use a claw-type tool to aid removal. When using a remover tool, rotate valve tappet back and forth to loosen it from gum or varnish that may have formed on the valve tappet.

Installation

NOTE: Lightly oil all bolt and stud threads before installation, except those specifying special sealant.

Using solvent, clean the cylinder head (6049) and valve sealing surfaces.

1. Lubricate each valve tappet and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

2. Install each valve tappet in bore from which it was removed. If new valve tappets are being installed, check for free fit in bore into which they are to be installed.

3. Align flats on side of valve tappets and install six valve tappet guide plates between adjacent valve tappets (make sure the word "up" is showing). Install two tappet guide plates and retainers and tighten four captive bolts to 10-14 Nm (7-10 lb-ft).

4. Dip each push rod end in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install push rods in their original position.

    CAUTION: Fulcrums must be fully seated in cylinder head and push rods must be seated in rocker arm sockets prior to final tightening.

5. Lubricate all rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A prior to assembly.

6. For each valve, rotate crankshaft (6303) until valve tappet rests onto heel (base circle) of camshaft lobe. Position rocker arms over push rods . Install fulcrums. Initially tighten fulcrum retaining bolts to 5 Nm (44 lb-in) MAX.

   Final-tighten fulcrum bolts to 25-35 Nm (19-25 lb-ft). For final tightening, the camshaft (6250) may be in any position.

7. Install lower intake manifold as outlined.

8. Install rocker arms as outlined.

9. Install upper intake manifold as outlined.

10. Install ignition wire routing clips and connect ignition wires to the spark plugs .

11. Start engine and check for oil or coolant leaks.
    
    
    
    
    

    Item	Part Number	Description
    1A	N605890-S2	Bolt (4 Req'd)
    2	6K564	Tappet Guide Plate and Retainer (2 Req'd)
    3	6500	Valve Tappet (12 Req'd)
    4	6K512	Valve Tappet Guide Plate (6 Req'd)
    5	6010	Cylinder Block
    A		Tighten to 10-14 Nm (7-10 Lb-Ft)