Ford AG9Z-6108-H Piston

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Before one could begin removing the piston and connecting rod assemblies, one requires the head of the cylinder and the oil pan. You should run your finger nail from down the bore and feel whether there is any ridge at the top dead center of the rings when they are at the maximum top ring travel in each cylinder; the ridges must be scraped out with a special tool to leave the cylinder bore smooth as per the manufacturer's recommendations in order not to cause breakages to the piston. Next, align the engine with the crankshaft in an upward manner and, on four-cylinder engines, also, pull out the balance shaft assembly; on the two vehicles with 3.5L engines, you should also take out the main bearing cap support brace. Before taking off the main bearing caps or destroying the connecting rods, check the CON ROD END PLAY with the help of the feeler gauges and it should be always lie within the stipulated limit. If the connecting rods or caps are not marked clearly, then paint or draw a mark around the connecting rods and caps then use a slowly rotating bolt to loosen the connecting rod cap bolts to the point where they can be removed by directly. Lift the first connecting rod cap and its bearing insert off gently; the connecting rod/s piston will then be pushed out of the top of the engine whose ridges must be smoothed. Do the same for the rest of the cylinders; after removal, secure the connecting rod caps and new bearings in their allocated rods keeping the old bearings in to preserve the bearing services. The pistons and cranks or connecting rods are now receptive of inspection and renewal. This step should be performed prior to fitting new pistons rings, the ring end gaps should be examined and the piston ring side clearance should be correct. Piston and connecting rod sets and new rings should be arranged for pairing up. Slide the first intermediate ring into the first cylinder and align it with the walls of the cylinder; check the thickness of the end gap with the feeler gauges and adjust it if necessary. The oil control ring should be placed on first then the mid and finally the top ring in the right position. Before installation, properly degrease the cylinder walls and edge blending and make certain that the crankshaft fits. Remove and clean the bearing housing surfaces to bear on; replace upper and lower bearing inserts with no lubricant applied. Space the gap of the piston ring 90 degrees apart, apply oil to the piston and rings and then use a piston ring compressor while 'installing'. Verify the connecting rod bearing oil clearance using Plastilge as used in determining the right size and condition of the bearing inserts. After making sure of the clearance, it is good to lubricate the bearing faces via grease or engine assembly lube, fit the rod cap with the new bolts and tighten to the degree of torque mentioned. Repeat the same with the other assemblies but make sure that they are also clean and well oriented. Following installation, spin the crankshaft to detect binding and measure/in Adjust connecting rod end-shaft clearance where new stock has been installed.

Ensure the cylinder walls are perfectly clean, the top edge of each cylinder bore is chamfered, and the crankshaft is in place.

Use paint or a marker to clearly identify each rod and cap by cylinder number.

Carefully scrape all traces of the Plastigage material off the rod journal or bearing face using your fingernail or the edge of a plastic card.