Subassemblies

Cylinder Head

Disassembly

1. Remove the exhaust manifolds (9430) , if required, and the spark plugs (12405) .

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

3. Compress the valve springs (6513) using Valve Spring Compressor T70P-6049-A. Remove the valve spring retainer keys (6518) and release the valve spring .

4. Remove the valve spring retainer sleeve (6517) , valve spring retainer (6514) , valve spring , valve stem seal (6571) and valve. Discard the valve stem seals . Identify all valve parts as to which cylinder they were removed from and whether intake or exhaust.

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

Assembly

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

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

2. Install the valve stem seal . Use a 5/8-inch deep well socket and a light mallet or hammer to seat the valve stem seal on the guide. Use the instructions found in the Valve Stem Seal Replacer T87L-6571-BH. Install the valve spring over the valve and then install the valve spring retainer . Compress the valve spring and install the valve spring retainer sleeve , if equipped, and valve spring retainer keys .
   
   
   
   
   

   Item	Part Number	Description
   1	6518	Valve Spring Retainer Key
   2	6514	Valve Spring Retainer (8 Req'd)
   3	6513	Valve Spring (16 Req'd)
   4	6571	Valve Stem Seal (16 Req'd)
   5	6505	Exhaust Valve (8 Req'd)
   6	6507	Intake Valve (8 Req'd)
   7	6514	Valve Spring Retainer (8 Req'd)
   8	6517	Valve Spring Retainer Sleeve (8 Req'd)

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

3. Measure the assembled height of the valve spring from the surface of the cylinder head spring pad to the underside of the valve spring retainer with dividers. Check the dividers against a scale. If the assembled height is greater than specification, install the necessary 0.76mm (0.03-inch) thick spacer(s) between the cylinder head spring pad and the valve spring to bring the assembled height to the recommended height.

4. Install the exhaust manifolds , if removed, and the spark plugs .
   
   
   
   

Pistons, Piston Pins and Rings

Disassembly

1. Remove the connecting rod bearings (6211) from the connecting rods (6200) and caps.

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

3. Remove the piston rings. Using an Arbor Press and Piston Pin Remover/Replacer T68P-6135-A, press the piston pin (6135) from the piston and connecting rod .
   
   
   
   
   

   Item	Part Number	Description
   1	—	Press Ram
   2	T68P-6135-A	Piston Remover/Replacer
   3	6135	Piston Pin
   4	—	Receiving Tube (Part of T68P-6135-A)
   5	—	Press Plates

Assembly

The piston , connecting rod and related parts are shown. Check the fit of a new piston in the cylinder bore before assembling the piston and piston pin to the connecting rod .

Item	Part Number	Description
1	6148	Lower Compression Piston Ring
2	6148	Oil Control Piston Ring
3	6108	Piston
4	6200	Connecting Rod
5	6211	Connecting Rod Bearing
6	—	Connecting Rod Cap (Part of 6200)
7	6212	Connecting Rod Nut (2 Req'd)
8	6214	Connecting Rod Bolt (2 Req'd)
9	6135	Piston Pin
10	6148	Upper Compression Piston Ring

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

1. Apply a light coat of engine oil XO-10W30-QSP or DSP or equivalent meeting Ford specification ESE-M2C153-E to all parts. Assemble the piston to the connecting rod with the cylinder number side of the connecting rod and the indentation notch in the piston positioned as shown.

   On replacement connecting rods , install the large chamfered side of the connecting rod bearing bore toward the crankshaft cheek; facing toward front of engine on RH bank connecting rods , and facing toward rear of engine on LH bank connecting rods .
   
   
   
   

2. Start the piston pin in the piston and connecting rod . (This may require a very light tap with a mallet). Using an arbor press, press the piston pin through the piston and connecting rod until the piston pin is centered in the piston .

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

    CAUTION: If the lower lands have high steps, the piston should be replaced.

4. Check the ring side clearance of the compression rings with a feeler gauge inserted between the ring and its lower land. Refer to Section 03-00. 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.

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

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 four 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 block cylinder 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 .

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.