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Cylinder Head: Disassembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.
CAUTION: Place the cylinder head on a cardboard or wood surface to prevent damage to the joint face.

    ALL CYLINDER HEADS 

    NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 1: Removing Hydraulic Lash Adjusters
    G01536764Courtesy of FORD MOTOR CO.
  1. Remove the hydraulic lash adjusters.
  2. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 2: Installing Special Tool Between Valve Spring Coils
    G01536765Courtesy of FORD MOTOR CO.
    3. NOTE: Windsor engine shown; Romeo engine similar.
    Fig 3: Compressing Valve Springs
    G01536766Courtesy of FORD MOTOR CO.
  3. Use the special tool to compress the valve springs.
    4. CAUTION: Keep the valves and valve spring retainer keys in order so they can be reinstalled in their original locations.
    NOTE: Shown without camshaft for clarity.
    Fig 4: Removing Valve Springs
    G01536767Courtesy of FORD MOTOR CO.
  4. Remove the valves.
    1. Remove the valve spring retainer keys.
    2. Remove the valve spring retainers.
    3. Remove the valve springs.
    4. Remove the valves.
  5. Remove the valve stem seals.
    Fig 5: Removing Valve Stem Seals
    G01536768Courtesy of FORD MOTOR CO.

    6. ROMEO CYLINDER HEADS (4.6L) 

    NOTE: The camshaft bearing caps must be reinstalled in their original locations. Record the camshaft bearing cap locations.
    Fig 6: Removing Bolts, Bearing Caps And Camshaft (Romeo Cylinder Heads 4.6L)
    G01536769Courtesy of FORD MOTOR CO.
  6. Remove the bolts, the bearing caps and the camshaft.
  7. Clean and inspect the camshaft bearing caps.
    • One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.
    Fig 7: Identifying Oil Flow Restriction Groove
    G01536770Courtesy of FORD MOTOR CO.

    8. WINDSOR CYLINDER HEADS (5.4L) 

    NOTE: The camshaft bearing caps must be reinstalled in their original locations. Record the camshaft bearing cap locations.
    Fig 8: Removing Bolts, Bearing Caps And Camshaft (Windsor Cylinder Heads 5.4L)
    G01536771Courtesy of FORD MOTOR CO.
  8. Remove the bolts, the bearing caps and the camshaft.
  9. Clean and inspect the camshaft bearing caps.
    • One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.
    Fig 9: Identifying Oil Flow Restriction Groove
    G01536772Courtesy of FORD MOTOR CO.

    10. ALL CYLINDER HEADS 

    CAUTION: 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.
    CAUTION: 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.
  10. Clean the cylinder head sealing surfaces.
    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.
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