Connecting Rod: Service and Repair
REMOVAL1. Drain engine cooling system.
2. Remove throttle body.
3. Remove intake manifold.
4. Remove cylinder heads.
5. Remove oil pan.
6. Remove oil pump and oil pump intermediate shaft.
7. Before removing the piston, inspect the top of each cylinder bore. If a ridge has formed at the top of the cylinder it must be removed before the piston is removed. Remove ridge as follows:
a. Turn crankshaft until the piston to be removed is at the bottom of cylinder bore.
b. Place a clean shop cloth over the piston head to collect cuttings.
c. Remove ridge using Rotunda Cylinder Ridge Reamer 014-00292 or equivalent. Never cut into the ring travel area more than 0.794 mm (0.031 inch) when removing the ridge.
8. Turn crankshaft until the piston to be removed is at the lowest point of its travel. If more than one piston is being removed, identify the pistons and connecting rod caps. Each component should be installed in its original position during assembly.
9. Remove connecting rod cap retaining nuts and cap.
NOTE: The cylinder number is stamped on the top of the piston. Matched letters are stamped on the sides of corresponding connecting rod and cap.
1O. Install a 50 mm (2 inch) piece of 3/8-inch fuel hose (or similar protector) over connecting rod bolts and push piston out through top of the cylinder bore.
CAUTION: I Use care to prevent damage to bearing surfaces or possible engine damage may occur.
11. Install connecting rod cap and hold in position with cap retaining nuts to keep from mixing parts.
12. If piston is to be disassembled. Piston
13. Inspect cylinder bore. If new piston rings are to be installed on the piston, a visible cross-hatch pattern should be obvious on cylinder bore wall.
14. If honing is required, remove glaze from cylinder wall using spring-loaded hone. Follow manufacturer's instructions when using this type of equipment.
NOTE: After honing, thoroughly clean cylinder bore using a detergent and water solution.
15. Check piston to cylinder bore clearance.
INSTALLATION
1. Lubricate cylinder wall and piston with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
NOTE: Lightly oil all retaining bolt and stud bolt threads before installation except those specifying special sealant.
2. Install a 50 mm (2 inch) piece of 3/8 inch fuel hose (or similar protector) on the connecting rod studs to protect crankshaft journal.
3. Install piston using Rotunda Piston Ring Compressor 014-00290 or equivalent.
CAUTION: As piston is tapped into bore with a wooden hammer handle, guide connecting rod onto crankshaft journal to avoid damage to bearing surfaces.
NOTE: Connecting rod and cap are not identified to cylinder position. Install the pistons in the same cylinders from which they were removed or to which they were fitted. The connecting rod and caps are identified with matching correlation letters. Letters on the connecting rod and cap must be on the same side when installed in the cylinder bore. If a connecting rod is transposed from one cylinder block or cylinder to another, new connecting rod bearings should be fitted.
Piston & Rod Assembly:
4. Make sure the notch in the piston dome faces the front of the engine and machine locating boss is facing the RH side of the engine.
5. Check connecting rod bearing clearance.
6. Lubricate bearing surfaces with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
7. Make sure connecting rod is seated on crankshaft journal. Install connecting rod cap. Tighten the cap retaining nuts to 31-39 Nm (23-28 ft. lbs.).
8. If necessary, check connecting rod side clearance.
9. Install oil pump and oil pump intermediate shaft. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
10. Install oil pan.
11. Install cylinder heads.
12. Install lower intake manifold.
13. Install valve covers and throttle body.
14. Fill crankcase with the correct viscosity and amount of engine oil XO-1OW30-QSP or -DSP.
15. Fill engine cooling system with specified coolant.
16. Start engine and check for oil, exhaust and coolant leaks.
17. Check and, if necessary, adjust accelerator cable and speed control actuator cable.