Subassemblies

Cylinder Head

Disassembly

1. Remove the water outlet connection and water thermostat (8575). Discard the oil cooler return tube gasket (6N789).

2. Remove the lower intake manifold (9424) and exhaust manifolds (9430) from the cylinder head (6049). Discard the gaskets.

3. Remove the spark plugs (12405).

4. Remove the deposits from the combustion chambers and valve heads with a scraper and a wire brush before removing the valves. Be careful not to scratch the cylinder head gasket surface.

5. Compress each valve spring (6513) using Valve Spring Compressor T70P-6049-A, then remove the valve spring retainer keys (6518) and release the valve spring.

   

6. Remove the valve spring retainer (6514), valve spring, valve stem seal (6571) and valve. Discard the valve stem seal.

   

   Item	Part Number	Description
   1	6518	Valve Spring Retainer Keys
   2	6514	Valve Spring Retainer
   3	6513	Valve Spring
   4	6571	Valve Stem Seal
   5	6507	Intake Valve
   6	6505	Exhaust Valve
   7	6513	Valve Spring
   8	6514	Valve Spring Retainer

Assembly

1. Lubricate the valve guides and valve stems with engine oil. Apply Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A to the tip of the valve stems.

2. Install each intake valve (6507) in the valve guide from which it was removed or to which it was fitted.

3. Install new valve stem seals. Use Valve Stem Seal Replacer T87L-6571-BH. Place the valve spring in position over the valve and install the valve spring retainer and sleeve, if so equipped. Compress the valve spring and install the valve spring retainer keys. Remove the compressor tool and rocker arm seat bolt.

4. Install the valve spring over the intake valve. Make sure the closed coil end is placed against the cylinder head.

5. Position valve spring retainer on the appropriate valve spring. Make sure a positive rotating retainer is used on all of the exhaust valves (6505).

6. Compress the spring. Install the valve spring retainer keys. Tap the retainers of each intake valve after assembly to seat the keys.

7. Measure the assembled height of the valve spring from the surface of the cylinder head spring pad to the underside of the spring retainer with dividers.

8.  CAUTION: Do not install 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 spring breakage or worn camshaft lobes.

   NOTE: Refer to Specifications for proper valve spring assembled height.

   Check the dividers against a scale. If the assembled height is greater than the specified limit, install the necessary 0.76mm (0.030-inch) thick spacer(s) between the cylinder head spring pad and the valve spring to bring the assembled height to the recommended dimension.

9. Install valve cover.

   

10. Make sure dowel pin is in place.

11. Install rear exhaust manifold with bolts in holes 16 and 15. Tighten bolts to 30-43 Nm (22-32 lb-ft).

12. Install front exhaust manifold and lifting eye with stud in hole 13 and bolt in hole 14. Snug stud and tighten bolt to 30-43 Nm (22-32 lb-ft).

13. Install intake manifold gasket (9439) over dowel pin and line up port openings in the cylinder head and intake manifold gasket.

14. Install the lower intake manifold onto dowel pin, then install remaining bolts.

    Exhaust Manifold/Lower Intake Manifold Assembly

    

    Item	Part Number	Description
    1	390754	Screw, 3/8-18 x 1.25
    2	9424	Intake Manifold (Lower)
    3	9439	Intake Manifold Gasket
    4	6049	Cylinder Head
    5	—	Dowel Pin 5/16 x 1.00 (Part of 6049)
    6	9430	Exhaust Manifold (Front)
    7	17A084	Lifting Eye
    8	391402	Stud, 3/8-16 x 3.57
    9	390530	Bolt, 3/8-16 x 1.31
    10	9430	Exhaust Manifold (Rear)
    11	9F485	EGR Valve Tube to Manifold Connector
    12	—	Hole For Heated Oxygen Sensor, used on California Certified Vehicles with E40D Transmission Only
    A	—	Refer to Text for Tightening Instructions

15. Tighten bolts to 30-43 Nm (22-32 lb-ft) in numerical sequence shown.

    

16. Using a new thermostat housing gasket coated with Perfect Seal Sealing Compound F2AZ-19554-AA or equivalent water-resistant sealer meeting Ford specifications ESE-M4G115-A and ESR-M18P2-A, install the water thermostat and water outlet connection. Refer to Section 03-03. Tighten the attaching bolts to 16-24 Nm (12-18 lb-ft).

17. Install spark plugs.

Pistons, Piston Pins and Rings

Disassembly

1. Remove the connecting rod bearing (6211) from the connecting rod and cap.

2. Mark the pistons and pins to ensure assembly with the same connecting rod (6200) and installation in the same cylinder from which they were removed.

3. Remove the piston rings. Using an arbor press and Piston Pin Remover/Replacer T81P-6135-A, press the piston pin from the piston and connecting rod.

   Refer to Section 03-00 for cleaning, inspection and repair procedures.

   Piston Pin

   

   Item	Part Number	Description
   1	—	Driver (Part of T81P-6135-A)
   2	—	Reversible Locator (Part of T68P-6135-A)
   3	—	Adapter (Part of T68P-6135-A)
   4	—	Cap (Part of T68P-6135-A)
   5	—	Pin Pusher (Part of T68P-6135-A)
   6	—	Piston Pin (Part of 6108)
   7	—	Receiving Tube (Part of T68P-6135-A)

Assembly

NOTE: Check the fit of a new piston in the cylinder bore before assembling the piston and piston pin to the connecting rod bearing. Refer to Section 03-00. The piston pin bore of a connecting rod and the diameter of the piston pin must be within Specifications listed at the end of this section.

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

2. Assemble the piston to the connecting rod with the bearing tang side of the connecting rod and the indentation notch in the piston positioned as shown.

   

3. Start the piston pin in the piston and connecting rod. Using an arbor press, press the piston pin through the piston and connecting rod until the pin is centered in the connecting rod. To install piston pin, use Piston Pin Remover/Replacer T81P-6135-A.

4. Check the end gap of all piston rings with a feeler gauge. End gap must be within Specifications listed at end of this section. Install the piston rings following the instructions on the package.

5. Check the ring side clearance of the compression rings with a feeler gauge inserted between the 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 steps, the piston should be replaced.

6.  CAUTION: Make sure the connecting rod bearings and the bearing bore in the connecting rod and cap are clean. Foreign material under the inserts will distort the bearing and cause a failure.

   Install the bearing inserts in the connecting rod and cap with the tangs fitting in the slots provided.

Oil Pump

Disassembly

1. Remove the oil pump screen cover and tube (6622) from the oil pump (6600) and remove the gaskets.

2. Remove the cover attaching bolts, then remove the cover. Remove the inner rotor and shaft assembly. Remove the outer race.

3. Drill a small hole and insert a self-threading sheet metal screw of the proper diameter into the oil pressure relief valve chamber cap and pull the cap out of the chamber. Remove the spring and plunger.

   Oil Pump Assembly — Typical

   

   Item	Part Number	Description
   1	—	Screw (Part of 6600)
   2	6A616	Oil Pump Relief Valve Plug
   3	6670	Oil Pump Relief Valve Spring
   4	6614	Oil Pump Relief Valve Repair Kit
   5	6600	Oil Pump
   6	—	Screw (Part of 6600)
   7	—	Identification Mark
   8	—	Bolt (Part of 6600)
   9	6616	Plate
   10	6608	Rotor and Shaft Assembly
   11	6626	Gasket
   12	6622	Oil Pump Screen Cover and Tube
   A	—	Tighten to 16-24 Nm (12-18 Lb-Ft)
   B	—	Tighten to 30-43 Nm (22-32 Lb-Ft)

Assembly

1. Clean, inspect and oil all parts thoroughly.

2. Install the oil pressure relief valve plunger, spring and a new cap.

3. NOTE: Make sure the dimple (identification mark) on the outer race is facing the same side as the identification mark on the rotor.

   Install the outer race and the inner rotor and shaft assembly.

4. Install the cover and tighten the cover attaching bolts to 30-43 Nm (22-32 lb-ft).