Subassemblies

Cylinder Head

Disassembly

1. Remove rocker arm fulcrum retaining bolts, fulcrums and rocker arms (6564) .

2. Remove exhaust manifolds (9430) if required, and spark plugs.

3. Clean carbon out of cylinder head combustion chambers before removing valves.

4. Compress valve spring (6513) using Valve Spring Compressor T81P-6513-A. Remove valve spring retainer keys (6518) and release valve springs .

5. Remove valve spring retainer (6514), valve stem seal (6571) , and valve. Discard valve stem seals identify all valve parts as to which cylinder they were removed from and whether intake or exhaust.
   
   
   
   
   

   Item	Part Number	Description
   1	6507	Intake Valve
   2	6505	Exhaust Valve
   3	6514	Lower Valve Spring Retainer
   4	6571	Valve Stem Seal
   5	6513	Valve Spring
   6	6514	Upper Valve Spring Retainer
   7	6518	Valve Spring Retainer Key
   8	6049	Cylinder Head

6. Clean, inspect and service cylinder head (6049) as required, or prepare to transfer all usable parts to a new cylinder head.

Assembly

All valves, valve stem seals and valve guides are to be lubricated with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Apply Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specifications ESR-M1C159-A and ESB-M1C93-A to valve tips before installation.

1. Install each valve in port from which it was removed or to which it was fitted.

   NOTE: Due to different leakage rates between intake and exhaust valve stems, valve stem seals must not be interchanged.

2. Install exhaust valve stem seal. Ensure valve stem seal is bottomed on guide.

3. Install intake valve stem seal. Valve stem seal must be bottomed on guide.

4. Install lower valve spring retainer.

5. Install valve spring over valve and then install upper valve spring retainer . Compress valve spring and install valve spring retainer keys .

   Do not install the spacers unless necessary. Use of spacers in excess of recommendations will result in over-stressing valve springs and overloading camshaft lobes which could lead to spring breakage and/or worn camshaft lobes.

6. Measure assembled height of valve spring from top of lower valve spring retainer to underside of upper valve spring retainer with dividers. Check dividers against a scale. If assembled height is greater than specification, install necessary 0.79mm (0.030 inch) thick spacer(s) between cylinder head spring pad and lower valve spring retainer to bring assembled height to recommended specification.

7. Position rocker arm and fulcrums on cylinder heads and install fulcrum retaining bolts. Do not tighten bolts. The bolts must be loose enough to allow rocker arm to be rotated to side.

8. Install exhaust manifold, if removed, and spark plugs (12405).

Pistons, Piston Pins and Rings

Disassembly

1. Remove connecting rod bearings from connecting rod (6200) and cap.

2. Remove piston rings using a suitable piston ring expander.

3. Mark piston (6108) to ensure assembly with same connecting rod and installation in same cylinders from which they were removed.

4. Using an arbor press and Piston Pin Remover and Replacer T68P-6135-A, press piston pin (6135) from piston and connecting rod .
   
   
   
   

Assembly

Check the fit of a new piston in the cylinder bore before assembling piston and piston pin to connecting rod . Refer to Section 03-00.

The piston pin bore of a connecting rod and diameter of piston pin must be within specification. Refer to Specifications as outlined.

1. Apply light coat of engine oil to all parts.

2. Start piston pin in piston and connecting rod (this may require a very light tap with a mallet). Using an Arbor Press and Piston Pin Remover and Replacer T68P-6135-A, press piston pin through piston until the pin is centered.
   
   
   
   

3. Check end gap of all piston rings. It must be within specification. Follow instructions contained on piston ring package and install piston rings. Refer to Section 03-00.

4. Check piston ring side clearance of compression rings with Feeler Gauge D81L-4201-A or equivalent, by inserting it between piston ring and its lower land. This gauge should slide freely around entire piston ring circumference without binding. Any wear that occurs will form a step at inner portion of lower land. If lower lands have high steps, piston should be replaced.

5. Ensure connecting rod bearings and bearing bore in connecting rod and cap are clean. Foreign material under connecting rod bearings will distort bearing and cause a failure. Install connecting rod bearings in connecting rod and cap with tangs fitting in slots provided.