Ford F2TZ-6108-FB Piston

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Be certain that cylinder walls in each of the pistons are immaculate and top edge of each cylinder is slightly beveled before fixing the piston and connecting rod assemblies and make sure that crankshaft has been fitted. Take off the cap of the number one connecting rod, and remember the marks made while removing the cap, and clean the bearing surface with a clean cloth. In the connecting rod bearing oil clearance check, clean the back side of the new upper bearing insert and place it in the connecting rod, the tab should fit into the recess, without hammering insert it. Do this for the lower bearing insert in the rod cap and ensure that all mating surfaces are clean and oil free. Align each of the gaps in the piston ring on the piston, apply clean engine oil on the piston and on the rings, then place the piston ring compressor in a manner that the skirt of the piston is slightly outside. Turn the crankshaft till the number one connecting rod journal is at BDC while apply some oil on the cylinder walls. Place the piston/connecting rod assembly into the cylinder bore with the arrow pointed towards the front of the engine, where the oil squirt hole on each of the connecting rod is to point to the middle of the engine. Rub your fingers across the ring compressor to ensure that it abuts the block and do the same to the piston while sliding the connecting rod over the crankshaft journal, if you feel any resistance at this stage, do not force the connecting rod onto the journal, nuts and bolts may be in the way. After the installation, check the oil clearance of connecting rod bearing using Plastigage, by making the width of the crushed material to follow the specifications. If the clearance is incorrect then ensure that no dirt or oil impacted on the clearance measurement as well as check on the journal diameter. Remove the plastigage from the rod journal and bearing face and apply a fresh layer of moly-base grease or engine assembly lube it to its respective areas and replace the connect rod and cap tighten the nuts to the specified torque value in a three step manner. Follow the same process for rest of the pistons and connecting rods that include cleaning the bearing inserts and the connecting rods, orientating the connecting rods correctly, lubricating the cylinder walls, and testing for binding with the help of rotating the Crank shaft. Last, but not the least is to check the connecting rod endplay and measure it with reference to the specifications written for it, if there is any variation, it will be advisable to resize the rods.

Prior to removing the piston and connecting rod assemblies, the cylinder head(s), oil pan, and oil pump must be taken off. Use your fingernail to check for any ridge at the upper limit of ring travel, approximately 1/4-inch down from the top of each cylinder. If ridges are present due to carbon deposits or cylinder wear, they must be completely removed with a ridge reamer before the pistons are taken out to avoid breakage. Ensure the tool does not cut into the ring travel area more than 1/32-inch. Once the ridges are removed, turn the engine upside-down with the crankshaft facing up. Before removing the connecting rods, check the end play using a dial indicator or feeler gauges, sliding them between the first connecting rod and the crankshaft throw until the play is eliminated. If the end play exceeds the service limit, new connecting rods may be necessary. If new rods or a new crankshaft are installed, the end play might fall below the specified minimum, requiring machining of the rods. Check the connecting rods and caps for identification marks; if not marked, use a center-punch or scribe to create indentations on each rod and cap. Loosen the connecting rod cap nuts half a turn at a time until they can be removed by hand, then take off the connecting rod cap and bearing insert without dropping the insert. To protect the crankshaft journal and cylinder wall during piston removal, slip a short length of plastic or rubber hose over each connecting rod cap bolt. Remove the bearing insert and push the connecting rod/piston assembly out through the top of the engine using a wooden or plastic hammer handle, ensuring all ridge material has been cleared. Repeat this process for the remaining cylinders. After removal, reassemble the connecting rod caps and bearing inserts in their respective rods and install the cap nuts finger tight to prevent accidental damage to the bearing surfaces. Avoid separating the pistons from the connecting rods.

Before the connecting rods are removed, check the endplay with feeler gauges. Slide them between the first connecting rod and the crankshaft throw until the play is removed. The endplay is equal to the thickness of the feeler gauge(s).

Check the piston-to-bore clearance by measuring the bore and the piston diameter. Make sure the pistons and bores are correctly matched. Measure the piston across the skirt, at a 90-degree angle to and in line with the piston pin. Subtract the piston diameter from the bore diameter to obtain the clearance. If it's greater than specified, the block will have to be rebored and new pistons and rings installed.

Clean the piston/rod assemblies with solvent and dry them with compressed air if available. Make sure the oil return holes in the back sides of the ring grooves are clear.

The connecting rod bearing oil clearance must be checked before the rod cap is permanently bolted in place.