Rebuilding a 6.2 Engine

[Navin jacob]

So I am doing something similar with my block and finally just got all the parts that I require. It has been more than 6 months going back on forth on some parts or not getting the right parts.

Little back story

I have 2012 with just above 100k kms on it when I got the truck it was perfect did not have any issues. It was a blast in the dunes since there was a Whipple stage 2 on it. On the 2nd outing once we were back I wanted to have the air filter cleaned out but to my shock, I noticed a kink on the connector pipe to the filter which let sand to go in. So then opened the supercharger and got it completely cleaned. Even did a couple of flushes to remove whatever we could from the bottom end without opening the engine because getting OEM parts in Dubai is a nightmare. So we drove the car a few days on road and then did another flush. (Oil was clean) So it seemed everything was fine so I took it to the dunes that weekend. While climbing a really tall dune engine just ceases without any indication.

Completely dismantled the engine and noticed a broken piston. So I gave the block to the machinist and they have advised that I need to oversize minimum by .055 because of the damage done to that particular cylinder. Since I did not want to sleeve it I decided to bore so checked locally if could find oversize of that size but none available. So then I contacted Livernois and they did have a set of .0835 oversize pistons in stock. I got those pistons and for the rods, since the lead time was more than a month and a half for the I beams from Manley. I did a little more research I was able to track down a set of H beams locally!!! (Lucky)

The route I am going is to have the block stronger and to make reliable power.

These are the aftermarket parts I have ordered

1. Ross racing pistons - Bore size 4.0865 - 9.5 comp ratio
   
2. Manley H-Beam Rods
3. FIRESTORM RAPTOR FUEL PUMP UPGRADE KIT - Not sure if am going to be installing this
   
4. POWERSTORM 2010-14 FORD F150 SVT RAPTOR 6.2 HEAD STUD KIT
   
5. POWERSTORM 2010-14 FORD F150 SVT RAPTOR 6.2 MAIN STUD KIT
   
6. POWERSTORM FORD F150 6.2L BILLET OIL PUMP GEARS
7. Clevite MAHLE Connecting Rod Bearing
8. Ron Davis Radiator
9. Mishimoto Ford F150 Raptor 6.2L V8 Silicone Radiator Hose Kit
   
10. Reische performance 170 thermostat
    
11. Exedy Racing 6R80 Auto Trans Clutch Pack Stage 2
12. Ford 6R80 Sure-Cool Thermal Control Bypass Valve by Superior
13. 6R80 Sonnax Performance Zip Kit
14. Stainless Works Raptor Long Tube Headers
15. DC Power Engineering'10-14 Ford Raptor 6.2L 270 Amp XP High Output Alternator
16. 65MM COBRA JET BILLET ALUMINUM THROTTLE BODY
    
17. Granatelli Motorsports Ignition Wires And Coil Pack Internals 28-2116HTBLB
18. NGK-6510 Spark Plug 6510 For the Ford Raptor Truck 6.2L
19. DeatschWerks 78 Lb/Hr Fuel injectors

And these are the Oem parts that i have ordered

1.AL3Z-6600-AB Oil Pump
2.AL3Z-6A642-B Oil Cooler
3.AL3Z-6L266-A Engine Timing Chain Tensioner - Passenger Side (RH)
4.AL3Z-6L266-B Engine Timing Chain Tensioner - Driver's Side (LH)
5.AU7Z-6079-C Kit - Gasket
6.BR3Z-6M280-E Solenoid
7.AL3Z-6268-A Timing Chain
8.6L2Z-8100-AC Radiator Cap
9.AL3Z-8260-B Upper Hose
10.BL3Z-8286-D Lower Hose
11.AL3Z-8501-D Water Pump Assembly
12.F1VY-8507-A Gasket
13.BL3Z-18472-A HVAC Heater Hose
14.BL3Z-18472-C HVAC Heater Hose
15.AU7Z-6E078-B Lower Gasket Kit
16.AL3Z-6571-AA Valve Seals
17.AL3Z-6020-A Gasket
18.AL3Z-6020-B Gasket
19.AL3Z-6020-D Gasket
20.XW4Z-6700-B Front Cover Seal
21.AL3Z-6B274-A Chain Guide - Driver's Side (LH)
22.AL3Z-6M256-A Chain Guide - Passenger Side (RH)
23.AL3Z-6211-A Engine Connecting Rod Bearing
24.AT4Z-6701-A Rear Main Seal
25.AL3Z-6K301-A Rear Main Seal Retainer
26.AL3Z-6710-A Oil Pan Gasket
27.AU7Z-6D309-AA Engine Crankshaft Main Bearing
28.AU7Z-6D309-DB Engine Crankshaft Thrust Washer

I am going to be doing an email tune through JDM once everything is put back


Attached a couple of pics of the damaged piston below

 

[BenBB]

So I am doing something similar with my block and finally just got all the parts that I require. It has been more than 6 months going back on forth on some parts or not getting the right parts.

Little back story

I have 2012 with just above 100k kms on it when I got the truck it was perfect did not have any issues. It was a blast in the dunes since there was a Whipple stage 2 on it. On the 2nd outing once we were back I wanted to have the air filter cleaned out but to my shock, I noticed a kink on the connector pipe to the filter which let sand to go in. So then opened the supercharger and got it completely cleaned. Even did a couple of flushes to remove whatever we could from the bottom end without opening the engine because getting OEM parts in Dubai is a nightmare. So we drove the car a few days on road and then did another flush. (Oil was clean) So it seemed everything was fine so I took it to the dunes that weekend. While climbing a really tall dune engine just ceases without any indication.

Completely dismantled the engine and noticed a broken piston. So I gave the block to the machinist and they have advised that I need to oversize minimum by .055 because of the damage done to that particular cylinder. Since I did not want to sleeve it I decided to bore so checked locally if could find oversize of that size but none available. So then I contacted Livernois and they did have a set of .0835 oversize pistons in stock. I got those pistons and for the rods, since the lead time was more than a month and a half for the I beams from Manley. I did a little more research I was able to track down a set of H beams locally!!! (Lucky)

The route I am going is to have the block stronger and to make reliable power.

These are the aftermarket parts I have ordered

1. Ross racing pistons - Bore size 4.0865 - 9.5 comp ratio
   
2. Manley H-Beam Rods
3. FIRESTORM RAPTOR FUEL PUMP UPGRADE KIT - Not sure if am going to be installing this
   
4. POWERSTORM 2010-14 FORD F150 SVT RAPTOR 6.2 HEAD STUD KIT
   
5. POWERSTORM 2010-14 FORD F150 SVT RAPTOR 6.2 MAIN STUD KIT
   
6. POWERSTORM FORD F150 6.2L BILLET OIL PUMP GEARS
7. Clevite MAHLE Connecting Rod Bearing
8. Ron Davis Radiator
9. Mishimoto Ford F150 Raptor 6.2L V8 Silicone Radiator Hose Kit
   
10. Reische performance 170 thermostat
    
11. Exedy Racing 6R80 Auto Trans Clutch Pack Stage 2
12. Ford 6R80 Sure-Cool Thermal Control Bypass Valve by Superior
13. 6R80 Sonnax Performance Zip Kit
14. Stainless Works Raptor Long Tube Headers
15. DC Power Engineering'10-14 Ford Raptor 6.2L 270 Amp XP High Output Alternator
16. 65MM COBRA JET BILLET ALUMINUM THROTTLE BODY
    
17. Granatelli Motorsports Ignition Wires And Coil Pack Internals 28-2116HTBLB
18. NGK-6510 Spark Plug 6510 For the Ford Raptor Truck 6.2L
19. DeatschWerks 78 Lb/Hr Fuel injectors

And these are the Oem parts that i have ordered

1.AL3Z-6600-AB Oil Pump
2.AL3Z-6A642-B Oil Cooler
3.AL3Z-6L266-A Engine Timing Chain Tensioner - Passenger Side (RH)
4.AL3Z-6L266-B Engine Timing Chain Tensioner - Driver's Side (LH)
5.AU7Z-6079-C Kit - Gasket
6.BR3Z-6M280-E Solenoid
7.AL3Z-6268-A Timing Chain
8.6L2Z-8100-AC Radiator Cap
9.AL3Z-8260-B Upper Hose
10.BL3Z-8286-D Lower Hose
11.AL3Z-8501-D Water Pump Assembly
12.F1VY-8507-A Gasket
13.BL3Z-18472-A HVAC Heater Hose
14.BL3Z-18472-C HVAC Heater Hose
15.AU7Z-6E078-B Lower Gasket Kit
16.AL3Z-6571-AA Valve Seals
17.AL3Z-6020-A Gasket
18.AL3Z-6020-B Gasket
19.AL3Z-6020-D Gasket
20.XW4Z-6700-B Front Cover Seal
21.AL3Z-6B274-A Chain Guide - Driver's Side (LH)
22.AL3Z-6M256-A Chain Guide - Passenger Side (RH)
23.AL3Z-6211-A Engine Connecting Rod Bearing
24.AT4Z-6701-A Rear Main Seal
25.AL3Z-6K301-A Rear Main Seal Retainer
26.AL3Z-6710-A Oil Pan Gasket
27.AU7Z-6D309-AA Engine Crankshaft Main Bearing
28.AU7Z-6D309-DB Engine Crankshaft Thrust Washer

I am going to be doing an email tune through JDM once everything is put back


Attached a couple of pics of the damaged piston below

View attachment 166630

View attachment 166631

Oh DAMN that piston got hot!! Melted right down, sand can do some damage that's for sure. I wonder if it clogged one of the squirters on that cylinder or took out the top ring and burned down from there? Hope you get everything in and back together soon, it's going to be even better!

 

[MTF]

So I am doing something similar with my block and finally just got all the parts that I require. It has been more than 6 months going back on forth on some parts or not getting the right parts.

Little back story

I have 2012 with just above 100k kms on it when I got the truck it was perfect did not have any issues. It was a blast in the dunes since there was a Whipple stage 2 on it. On the 2nd outing once we were back I wanted to have the air filter cleaned out but to my shock, I noticed a kink on the connector pipe to the filter which let sand to go in. So then opened the supercharger and got it completely cleaned. Even did a couple of flushes to remove whatever we could from the bottom end without opening the engine because getting OEM parts in Dubai is a nightmare. So we drove the car a few days on road and then did another flush. (Oil was clean) So it seemed everything was fine so I took it to the dunes that weekend. While climbing a really tall dune engine just ceases without any indication.

Completely dismantled the engine and noticed a broken piston. So I gave the block to the machinist and they have advised that I need to oversize minimum by .055 because of the damage done to that particular cylinder. Since I did not want to sleeve it I decided to bore so checked locally if could find oversize of that size but none available. So then I contacted Livernois and they did have a set of .0835 oversize pistons in stock. I got those pistons and for the rods, since the lead time was more than a month and a half for the I beams from Manley. I did a little more research I was able to track down a set of H beams locally!!! (Lucky)

The route I am going is to have the block stronger and to make reliable power.

These are the aftermarket parts I have ordered

1. Ross racing pistons - Bore size 4.0865 - 9.5 comp ratio
   
2. Manley H-Beam Rods
3. FIRESTORM RAPTOR FUEL PUMP UPGRADE KIT - Not sure if am going to be installing this
   
4. POWERSTORM 2010-14 FORD F150 SVT RAPTOR 6.2 HEAD STUD KIT
   
5. POWERSTORM 2010-14 FORD F150 SVT RAPTOR 6.2 MAIN STUD KIT
   
6. POWERSTORM FORD F150 6.2L BILLET OIL PUMP GEARS
7. Clevite MAHLE Connecting Rod Bearing
8. Ron Davis Radiator
9. Mishimoto Ford F150 Raptor 6.2L V8 Silicone Radiator Hose Kit
   
10. Reische performance 170 thermostat
    
11. Exedy Racing 6R80 Auto Trans Clutch Pack Stage 2
12. Ford 6R80 Sure-Cool Thermal Control Bypass Valve by Superior
13. 6R80 Sonnax Performance Zip Kit
14. Stainless Works Raptor Long Tube Headers
15. DC Power Engineering'10-14 Ford Raptor 6.2L 270 Amp XP High Output Alternator
16. 65MM COBRA JET BILLET ALUMINUM THROTTLE BODY
    
17. Granatelli Motorsports Ignition Wires And Coil Pack Internals 28-2116HTBLB
18. NGK-6510 Spark Plug 6510 For the Ford Raptor Truck 6.2L
19. DeatschWerks 78 Lb/Hr Fuel injectors

And these are the Oem parts that i have ordered

1.AL3Z-6600-AB Oil Pump
2.AL3Z-6A642-B Oil Cooler
3.AL3Z-6L266-A Engine Timing Chain Tensioner - Passenger Side (RH)
4.AL3Z-6L266-B Engine Timing Chain Tensioner - Driver's Side (LH)
5.AU7Z-6079-C Kit - Gasket
6.BR3Z-6M280-E Solenoid
7.AL3Z-6268-A Timing Chain
8.6L2Z-8100-AC Radiator Cap
9.AL3Z-8260-B Upper Hose
10.BL3Z-8286-D Lower Hose
11.AL3Z-8501-D Water Pump Assembly
12.F1VY-8507-A Gasket
13.BL3Z-18472-A HVAC Heater Hose
14.BL3Z-18472-C HVAC Heater Hose
15.AU7Z-6E078-B Lower Gasket Kit
16.AL3Z-6571-AA Valve Seals
17.AL3Z-6020-A Gasket
18.AL3Z-6020-B Gasket
19.AL3Z-6020-D Gasket
20.XW4Z-6700-B Front Cover Seal
21.AL3Z-6B274-A Chain Guide - Driver's Side (LH)
22.AL3Z-6M256-A Chain Guide - Passenger Side (RH)
23.AL3Z-6211-A Engine Connecting Rod Bearing
24.AT4Z-6701-A Rear Main Seal
25.AL3Z-6K301-A Rear Main Seal Retainer
26.AL3Z-6710-A Oil Pan Gasket
27.AU7Z-6D309-AA Engine Crankshaft Main Bearing
28.AU7Z-6D309-DB Engine Crankshaft Thrust Washer

I am going to be doing an email tune through JDM once everything is put back


Attached a couple of pics of the damaged piston below

View attachment 166630

View attachment 166631

I would get the Billet gear set and pump housing from livernois, unless the stock housing is that much cheaper
Livernois Motorsports

 

[BenBB]

I wouldn't go with a stock oil pump/gears
Get the Billet gear set and pump housing from livernois!!!
Livernois Motorsports

I already replaced my engine because the stock oil pump gears failed.
There are quite a lot of SC Raptors that have had the oil pump gears fail.
Supercharger is hard on the oil pump gears.

He's got 'em down, #6. Damn yours failed? I've seen lots of threads saying you need them for superchargers but didn't know of any actual failures, possibly @Navin jacob's did as well.

 

[MTF]

@BenBB Yeah, I saw that and edited my post one minute before you commented. LOL

Both JDM and Livernois have sold hundreds of the Billet Gear sets, there are quite a few confirmed oil gear failures on this forum.
A lot of it is because of harsh shifting Tunes like the Roush Tune, wheel hop, people just beating the crap out of their truck and Whipple's pushing past 560 rwhp.

JDM posted this
Roush Raptor Oil Pump failure and Resurrection | Ford Raptor Forums

I don't remember who sent me these (Biggest or Cubdriver) but you can see all the stress cracks and the cracks you see now is because the inner gear exploded outwards at 6000 rpms.
It's just a matter of time before it goes.




Looks like this new, I received #6 of the first product run.

 

[Navin jacob]

Oh DAMN that piston got hot!! Melted right down, sand can do some damage that's for sure. I wonder if it clogged one of the squirters on that cylinder or took out the top ring and burned down from there? Hope you get everything in and back together soon, it's going to be even better!

The plastic valve cover had a crack. Could that be because of too much pressure? I am going to replace it with the valve cover that came in the 2010/2011 Raptor i think they were magnesium or aluminium.

Is the pump housing any different from the Oem? When i checked with livernois they did not have the pump in stock. So i only bought the billet gears and a Oem pump, Will swap the oem gears with the billet gears. I haven't open the old one to the see the condition of it. I shall do it shortly.


Do you think i should be replacing anything else?

 

[MTF]

Those plastic valve covers are prone to cracking, doesn't matter if NA or SC
The cast alloy valves covers are hard to find, may be post in "want to buy section" on this forum.

I don't believe there is a difference, I just replaced the gears in mine but it was a new reman long block anyway.
Melling, makes a billet oil pump kit with two springs to increase oil pressure 10 psi. not sure if it's needed.

I also see you bought the fuel pump, I don't believe you're going to need it if you only use the Twin 65mm TB.

Oil/Air separator catch can, is the only thing I don't see on your list but you probably have that all ready.

What are you doing for cats for the headers?

 

[Navin jacob]

I actually don't have a catch can. I did not find one which was specifically for the Whipple system. Can you suggest a kit?

I was able to salvage one from the junk yard. I tried a couple of times to order it from Tasca/Ebay but for my bad luck there was no eta on when it could be ready to ship.

JDM advised not to use the 68mm Whipple TB and to get the Ford performance 65mm TB since they are easier to tune and less susceptible to wear plus the difference in power is only 5 Bhp. I don't think I will be installing the new pump.

I have the stainless works long tube headers without cats

 

[MTF]

LOL, must be nice not to have to worry about passing a OBDII smog test.

Any catch can for the Raptor will work. My only suggestion is getting a large can setup.
And you only need one for the passenger side, the drivers side is for fresh air intake.

I went with Moroso easy drain
Moroso SEPARATOR, AIR OIL, CATCH CAN, FORD RAPTOR 6.2, 10-14

 

[PD1744]

So I am doing something similar with my block and finally just got all the parts that I require. It has been more than 6 months going back on forth on some parts or not getting the right parts.

Little back story

I have 2012 with just above 100k kms on it when I got the truck it was perfect did not have any issues. It was a blast in the dunes since there was a Whipple stage 2 on it. On the 2nd outing once we were back I wanted to have the air filter cleaned out but to my shock, I noticed a kink on the connector pipe to the filter which let sand to go in. So then opened the supercharger and got it completely cleaned. Even did a couple of flushes to remove whatever we could from the bottom end without opening the engine because getting OEM parts in Dubai is a nightmare. So we drove the car a few days on road and then did another flush. (Oil was clean) So it seemed everything was fine so I took it to the dunes that weekend. While climbing a really tall dune engine just ceases without any indication.

Completely dismantled the engine and noticed a broken piston. So I gave the block to the machinist and they have advised that I need to oversize minimum by .055 because of the damage done to that particular cylinder. Since I did not want to sleeve it I decided to bore so checked locally if could find oversize of that size but none available. So then I contacted Livernois and they did have a set of .0835 oversize pistons in stock. I got those pistons and for the rods, since the lead time was more than a month and a half for the I beams from Manley. I did a little more research I was able to track down a set of H beams locally!!! (Lucky)

The route I am going is to have the block stronger and to make reliable power.

These are the aftermarket parts I have ordered

1. Ross racing pistons - Bore size 4.0865 - 9.5 comp ratio
   
2. Manley H-Beam Rods
3. FIRESTORM RAPTOR FUEL PUMP UPGRADE KIT - Not sure if am going to be installing this
   
4. POWERSTORM 2010-14 FORD F150 SVT RAPTOR 6.2 HEAD STUD KIT
   
5. POWERSTORM 2010-14 FORD F150 SVT RAPTOR 6.2 MAIN STUD KIT
   
6. POWERSTORM FORD F150 6.2L BILLET OIL PUMP GEARS
7. Clevite MAHLE Connecting Rod Bearing
8. Ron Davis Radiator
9. Mishimoto Ford F150 Raptor 6.2L V8 Silicone Radiator Hose Kit
   
10. Reische performance 170 thermostat
    
11. Exedy Racing 6R80 Auto Trans Clutch Pack Stage 2
12. Ford 6R80 Sure-Cool Thermal Control Bypass Valve by Superior
13. 6R80 Sonnax Performance Zip Kit
14. Stainless Works Raptor Long Tube Headers
15. DC Power Engineering'10-14 Ford Raptor 6.2L 270 Amp XP High Output Alternator
16. 65MM COBRA JET BILLET ALUMINUM THROTTLE BODY
    
17. Granatelli Motorsports Ignition Wires And Coil Pack Internals 28-2116HTBLB
18. NGK-6510 Spark Plug 6510 For the Ford Raptor Truck 6.2L
19. DeatschWerks 78 Lb/Hr Fuel injectors

And these are the Oem parts that i have ordered

1.AL3Z-6600-AB Oil Pump
2.AL3Z-6A642-B Oil Cooler
3.AL3Z-6L266-A Engine Timing Chain Tensioner - Passenger Side (RH)
4.AL3Z-6L266-B Engine Timing Chain Tensioner - Driver's Side (LH)
5.AU7Z-6079-C Kit - Gasket
6.BR3Z-6M280-E Solenoid
7.AL3Z-6268-A Timing Chain
8.6L2Z-8100-AC Radiator Cap
9.AL3Z-8260-B Upper Hose
10.BL3Z-8286-D Lower Hose
11.AL3Z-8501-D Water Pump Assembly
12.F1VY-8507-A Gasket
13.BL3Z-18472-A HVAC Heater Hose
14.BL3Z-18472-C HVAC Heater Hose
15.AU7Z-6E078-B Lower Gasket Kit
16.AL3Z-6571-AA Valve Seals
17.AL3Z-6020-A Gasket
18.AL3Z-6020-B Gasket
19.AL3Z-6020-D Gasket
20.XW4Z-6700-B Front Cover Seal
21.AL3Z-6B274-A Chain Guide - Driver's Side (LH)
22.AL3Z-6M256-A Chain Guide - Passenger Side (RH)
23.AL3Z-6211-A Engine Connecting Rod Bearing
24.AT4Z-6701-A Rear Main Seal
25.AL3Z-6K301-A Rear Main Seal Retainer
26.AL3Z-6710-A Oil Pan Gasket
27.AU7Z-6D309-AA Engine Crankshaft Main Bearing
28.AU7Z-6D309-DB Engine Crankshaft Thrust Washer

I am going to be doing an email tune through JDM once everything is put back


Attached a couple of pics of the damaged piston below

View attachment 166630

View attachment 166631

Sounds like an epic build man!! Much more involved than mine. I'm just hoping I can get it back together and functioning
Super lucky scoring those H-Beams man. That's awesome! Funny, my wife and I are actually looking at going to Dubai in August for our 10 year anniversary. Never been.

Update on mine. The remaining parts (Tasca order) showed up a couple days ago. Took like 3 weeks. Haven't received any updates from the machine shop, but then again I haven't followed up for any either as I'm really in no rush to get cranking on it or to pay that bill lol. Gonna reach out to my tuner and see if he'll do me a 'before' dyno run and then 'tune' package.