Oil Pump

Disassembly

1. If necessary, remove oil bypass filter (6714) .

2. Remove oil pump and filter body (6603) to engine front cover retaining bolts and remove oil pump and filter body from engine front cover (6019) .

3. Lift pump gears out of pocket in oil pump and filter body .

4. Remove oil pump body seal (6C639) and discard.

5. Clean sealing surfaces of engine front cover and oil pump and filter body .

6. Using a straightedge and feeler gauge, measure across mounting surface of engine front cover for wear or warpage.

7. If surface is out of flat by more than 0.04mm (0.0016 inch), replace the engine front cover as outlined.

Assembly

 CAUTION: Failure to properly coat the oil pump gears may result in failure of the pump to prime when engine is started.

1. Lightly pack gear pocket with petroleum jelly or coat all gear surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Do not use chassis lubricants.

2. Install gears in oil pump and filter body pocket. Ensure petroleum jelly fills all voids between gears and pockets.

3. Position oil pump body seal and install oil pump and filter body to engine front cover using alignment dowels on engine front cover .

4. Tighten oil pump and filter body retaining bolts to 25-30 Nm (18-22 lb-ft) for M8 bolts and 8-11 Nm (6-8 lb-ft) for M6 bolts.

Oil Pressure Relief Valve

Removal

1. After drilling a hole through valve plug, remove plug with a slide hammer or by prying.

2. Remove spring and pressure relief valve from bore.

Inspection

1. Thoroughly clean pressure relief valve bore and pressure relief valve to remove any metal chips which may have entered bore as a result of drilling operation.

2. Inspect pressure relief valve and valve bore for wear, scoring or galling. If inspection determines part(s) to be unserviceable, replace pressure relief valve and/or oil pump and filter body .

3. Check clearance between pressure relief valve and bore. The valve should slip into bore without side play or binding.

4. Check spring for signs of fatigue or collapse.

Installation

1. Lubricate pressure relief valve with engine oil and install in bore. The end with smaller diameter goes in first.

2. Position spring in bore.

3. Install a new plug. The plug can be tapped into bore using a plastic tipped hammer. Ensure plug is 0-0.25mm (0-0.010 inch) below machined surface.

Oil Pump Intermediate Shaft

Removal

1. Remove camshaft position sensor (CMP sensor) (6B288) and camshaft position sensor housing as outlined in Section 03-14.

2. Separate oil pump intermediate shaft (6A618) from camshaft position sensor housing shaft.
   
   
   
   
   

   Item	Part Number	Description
   1A	—	Screw and Washer (2 Req'd)
   2B	12270	Hold-Down Clamp
   3	6019	Engine Front Cover
   4	6A618	Oil Pump Intermediate Shaft
   5	—	Housing (Part of 6B288)
   6	6B288	Camshaft Position Sensor
   A		Tighten to 2.5-3.5 Nm (22-31 Lb-In)
   B		Tighten to 20-30 Nm (15-22 Lb-Ft)

Installation

1. Push lock ring end of oil pump intermediate shaft into camshaft position sensor housing shaft.

   NOTE: Install camshaft position sensor housing/ oil pump intermediate shaft as an assembly, ensuring that end of oil pump intermediate shaft is seated in oil pump drive gear.

2. Install oil pump intermediate shaft and camshaft position sensor as outlined in Section 03-14.

3. Install hold-down clamp (12270). Tighten to 20-30 Nm (15-22 lb-ft).

Hydraulic Valve Tappet

The internal parts of each hydraulic valve tappet (6500) are matched sets. Do not intermix the parts. Keep the valve tappets intact until they are to be cleaned. Valve tappets should always be tested after assembly. Refer to the cleaning, inspection and test procedures in Section 03-00.

Disassembly

Disassemble and assemble each valve tappet separately. Identify the valve tappets so they can be installed in their original bores.

1. Grasp the lock ring with needlenose pliers to release it from the groove. It may be necessary to depress the plunger to fully release lock ring.

2. Remove the push rod cup, metering valve (disc), plunger and spring.

3. Remove the plunger assembly, the check valve and the check valve retainer and plunger spring. Carefully remove the plunger spring, the check valve retainer and the check valve disc from the plunger.

Assembly

1. Place the plunger upside down on a clean work bench.

2. Place the check valve (disc or ball check) in position over the oil hole on the bottom of the plunger. Set the check valve spring on top of the check valve (disc or ball check).

3. Position the check valve retainer over the check valve and spring and push the retainer down into place on the plunger.

4. Place the plunger spring and then the plunger (open end up) into the valve tappet body.

5. Position the metering valve (disc) in the plunger, and then place the push rod cup in the plunger.

6. Depress the plunger and position the closed end of the lock ring in the groove of the valve tappet body. With the plunger still depressed, position the open ends of the lock ring in the groove. Release the plunger and then depress it again to fully seat the lock ring.

7. Use the Hydraulic Tappet Leakdown Tester TOOL-6500-E or equivalent to fill the valve tappets with test fluid.
   
   
   
   

Cylinder Block Assembly

Disassembly

1. Mount the engine in a work stand and remove all parts not furnished with the new cylinder block (6010) , following the procedures in Removal and Installation.

2. Remove the cylinder head to block dowels (6A008) and the cylinder block drain plugs.

3. Remove the used cylinder block from the work stand.

Assembly

1. Clean the gasket and seal surfaces of all serviceable parts and assemblies.

2. Position the new cylinder block in a work stand and install the cylinder head to block dowels and cylinder block drain plugs.

3. Transfer all serviceable parts removed from the used cylinder block , following the procedures in Removal and Installation.

4. Check all assembly clearances and correct as necessary.

Cylinder Block, Bare

Before replacing a cylinder block , determine if it is serviceable. If so, make the necessary service. Refer to Section 03-00.

Disassembly

1. Completely disassemble the used engine, following the procedures in Removal and Installation.

2. Remember to ridge ream the cylinder bores before removing pistons (6108) .

3. Remove the cylinder head to block dowels and the cylinder block drain plugs.

Assembly

1. Clean the gasket and seal surfaces of all serviceable parts and assemblies.

2. Position the new cylinder block in a work stand and install the cylinder head to block dowels and the cylinder block drain plugs.

3. Transfer all serviceable parts removed from the used cylinder block , following the procedures in Removal and Installation.

4. Check all assembly clearances and correct as necessary.