Cylinder Head: Removal

Cylinder heads 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
2. Remove the engine. For additional information, refer to Engine  in the Removal portion of this article.
3. Remove the bolts and the flexplate.
Fig 1: Locating Flexplate Bolts
Courtesy of FORD MOTOR CO.
4. Remove the engine/transmission spacer plate.
Fig 2: Engine-To-Transmission Spacer Plate
Courtesy of FORD MOTOR CO.
5. Using the Engine Lifting Bracket Set, mount the engine on a suitable engine stand.
Fig 3: Mounting Engine On A Suitable Engine Stand
Courtesy of FORD MOTOR CO.
6. Remove the bolts and the RH engine mount.
Fig 4: Engine Mount Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
7. Remove the drain plugs from the engine block. Allow the coolant to completely drain.
   • Install the drain plugs when finished.
   • To install, tighten to 20 Nm (177 lb-in).
Fig 5: Engine Block Drain Plug
Courtesy of FORD MOTOR CO.
8. Remove the bolt and the battery cables from the engine.
Fig 6: Bolt
Courtesy of FORD MOTOR CO.
9. Disconnect the EGR tube from the exhaust manifold.
Fig 7: EGR Tube At Exhaust Manifold
Courtesy of FORD MOTOR CO.
10. Disconnect the 8 ignition coil electrical connectors (4 shown in illustration).
Fig 8: Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
11. Disconnect the 8 fuel injector electrical connectors (4 shown in illustration).
Fig 9: Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
12. Remove the bolts and the intake manifold shield.
Fig 10: Intake Manifold Shield
Courtesy of FORD MOTOR CO.
13. Remove the crankcase ventilation tube.
Fig 11: Crankcase Ventilation Tube
Courtesy of FORD MOTOR CO.
14. Disconnect the generator electrical connector and detach the wire harness retainers.
Fig 12: Electrical Connector And Wire Harness Retainer
Courtesy of FORD MOTOR CO.
15. Remove the generator mounting bracket.
    • Remove the 4 bolts.
    • Remove the bracket.
Fig 13: Generator Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
16. Disconnect the throttle control and the Throttle Position (TP) sensor electrical connectors.
Fig 14: Locating Throttle Control And Throttle Position (TP) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
17. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
Fig 15: Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
18. Disconnect the Camshaft Position (CMP) sensor electrical connector.
Fig 16: Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
19. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
Fig 17: Radio Ignition Interference Capacitor
Courtesy of FORD MOTOR CO.
20. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine.
Fig 18: Fuel Charging Wiring In Crash Bracket
Courtesy of FORD MOTOR CO.
21. Disconnect the EGR tube nut from the EGR system module.
Fig 19: EGR Tube Nut At EGR
Courtesy of FORD MOTOR CO.
22. Remove the generator.
    1. Remove the 2 bolts.
    2. Remove the generator.
Fig 20: Generator & Bolts
Courtesy of FORD MOTOR CO.
23. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
Fig 21: Removing Crash Bracket Bolt
Courtesy of FORD MOTOR CO.
24. Remove the intake manifold crash bracket stud bolt.
Fig 22: Intake Manifold Crash Bracket Stud Bolt
Courtesy of FORD MOTOR CO.
25. Remove the 8 bolts and the 8 ignition coils (4 shown in illustration).
Fig 23: Ignition Coils & Bolts
Courtesy of FORD MOTOR CO.
26. Remove the 2 bolts and the coolant outlet adapter.
Fig 24: Coolant Outlet Adapter & Bolts
Courtesy of FORD MOTOR CO.
27. Remove the thermostat.
Fig 25: Thermostat
Courtesy of FORD MOTOR CO.
28. Remove the bolts and the intake manifold.
    • Discard the intake manifold gasket.
Fig 26: Intake Manifold & Bolts
Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
29. Clean the sealing surfaces.
Fig 27: Intake Manifold Sealing Surfaces
Courtesy of FORD MOTOR CO.
30. Remove the coolant bypass tube.
    1. Remove the retaining nut.
    2. Remove the ground strap.
    3. Remove the coolant bypass tube.
Fig 28: Coolant Bypass Tube & Nut
Courtesy of FORD MOTOR CO.
31. Loosen the studs and bolts and remove the LH valve cover.
    • Clean the mating surface and discard gasket.
Fig 29: Valve Cover Bolts
Courtesy of FORD MOTOR CO.
32. Loosen the studs and bolts and remove the RH valve cover.
    • Clean the mating surface and discard the gasket.
Fig 30: RH Valve Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
33. Remove the spark plugs.
Fig 31: Spark Plug
Courtesy of FORD MOTOR CO.
34. Position the lobe of the camshaft up.
Fig 32: Positioning Camshaft Lobe Up
Courtesy of FORD MOTOR CO.
35. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
Fig 33: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
36. Use the Valve Spring Compressor to compress the valve springs and remove the camshaft roller followers.
Fig 34: Compressing Valve Spring
Courtesy of FORD MOTOR CO.
NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
37. Remove the 16 hydraulic lash adjusters (4 shown in illustration).
Fig 35: Lash Adjusters
Courtesy of FORD MOTOR CO.
38. Remove the bolt and the belt idler pulley.
Fig 36: Belt Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
39. Remove the coolant pump pulley.
Fig 37: Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
40. Remove the crankshaft pulley bolt.
Fig 38: Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
41. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
Fig 39: Removing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
42. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front oil seal.
Fig 40: Removing Crankshaft Front Seal Using Special Tool
Courtesy of FORD MOTOR CO.
43. Remove the front 4 oil pan bolts.
Fig 41: Front Oil Pan Bolts
Courtesy of FORD MOTOR CO.
NOTE: Correct fastener location is essential for the installation. Record fastener location.
44. Remove the 15 fasteners in the sequence shown in illustration.
Fig 42: Engine Front Cover Fastener Removal/Tightening Sequence
Courtesy of FORD MOTOR CO.
45. Remove the engine front cover from the cylinder block.
    • Clean the sealing surfaces and discard the gaskets.
Fig 43: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.
46. Remove the crankshaft sensor ring.
Fig 44: View Of Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
47. Position the crankshaft with the keyway at the 12 o'clock position.
Fig 45: Crankshaft With Keyway At 12 O'clock Position
Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
48. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
Fig 46: Identifying Timing Chain Tensioning System
Courtesy of FORD MOTOR CO.
49. Remove the LH and RH timing chains and the crankshaft sprocket.
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain from the crankshaft sprocket.
    • Repeat for the LH timing chain and crankshaft sprocket.
Fig 47: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
Courtesy of FORD MOTOR CO.
50. Remove both timing chain guides.
    1. Remove the bolts.
    2. Remove the LH timing chain guide.
    3. Remove the bolts.
    4. Remove the RH timing chain guide.
Fig 48: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.

RH cylinder head 

51. Remove the RH exhaust manifold.
    1. Remove the nuts and discard.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
Fig 49: RH Exhaust Manifold
Courtesy of FORD MOTOR CO.
52. Remove and discard the 8 RH exhaust manifold studs.

LH cylinder head 

53. Remove the LH exhaust manifold.
    1. Remove the nuts and discard.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gaskets.
Fig 50: Exhaust Manifold, Nuts & Gasket
Courtesy of FORD MOTOR CO.
54. Remove and discard the 8 LH exhaust manifold studs.
55. Remove the bolt and the oil level indicator tube.
Fig 51: Locating Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.

Both cylinder heads 

56. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
57. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.
Fig 52: Identifying Special Tool (303-572)
Courtesy of FORD MOTOR CO.

RH cylinder head 

NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
58. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
Fig 53: Identifying Cylinder Head Gasket And Bolts
Courtesy of FORD MOTOR CO.

LH cylinder head 

NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
59. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
Fig 54: Identifying Cylinder Head Bolts
Courtesy of FORD MOTOR CO.

Both cylinder heads 

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
60. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
NOTE: LH shown in illustration, RH similar.
61. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
Fig 55: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
Courtesy of FORD MOTOR CO.