As one who has rebuilt many of these engines and done dozens of compression checks, allow me to say the following: 1) About the bext compression you'll see is 350-400 max. That's at a decent cranking speed. When Ford first came out with the 450-500 figure, that was with the engine running at idle, which they later changed to a cranking test. Keep in mind that if your battery is weak and the cranking speed is sluggish, your compression will be lower. Also, you do have all the injectors out when you do this, right? 2) Piston deck height is VERY important. Not only were there different types of pistons, there were also different thicknesses of head gaskets. Using a thick gasket where a thin one should be will definitely cause hard starting when cold. It's amazing the difference just .020" can make. 3) I seriously doubt you can mix up the pistons (gas to diesel) and still be able to start the thing. According to the picture I have, the gas pistons have cutouts on the tops for valve reliefs.
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