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Cylinder Heads

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SPECIAL TOOL(S) 

Fig 1: Identifying Special Tool(s)
G02763989Courtesy of FORD MOTOR CO.

MATERIAL 

MATERIAL SPECIFICATION

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -

    BOTH CYLINDER HEADS 

  1. Remove the engine. For additional information, refer to ENGINE .
  2. Remove the bolts and the flexplate.
    Fig 2: Removing Bolts And Flexplate
    G02763990Courtesy of FORD MOTOR CO.
    3. CAUTION: To prevent damage to the oil pan, use care when lowering the engine.
  3. Lower the engine onto wooden blocks.
  4. Remove the special tool.
    Fig 3: Removing Special Tool
    G02763991Courtesy of FORD MOTOR CO.
  5. Install the special tool.
    Fig 4: Installing Special Tool
    G02763992Courtesy of FORD MOTOR CO.
  6. Install the special tool.
    Fig 5: Installing Special Tool
    G02763993Courtesy of FORD MOTOR CO.
  7. Mount the engine on a suitable work stand.
  8. Remove the special tool.
    Fig 6: Removing Special Tool
    G02763994Courtesy of FORD MOTOR CO.
  9. Remove the special tool.
    Fig 7: Removing Special Tool
    G02763995Courtesy of FORD MOTOR CO.
  10. Remove the RH engine mount.
    Fig 8: Removing RH Engine Mount
    G02763996Courtesy of FORD MOTOR CO.
    11. NOTE: LH shown, RH similar.
    Fig 9: Removing Cylinder Block Drain Plugs
    G02763997Courtesy of FORD MOTOR CO.
  11. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
  12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 10: Disconnecting LH Radio Frequency Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G02763998Courtesy of FORD MOTOR CO.
  13. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 11: Disconnecting Camshaft Position (CMP) sensor Electrical Connector
    G02763999Courtesy of FORD MOTOR CO.
  14. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 12: Disconnecting RH Radio Frequency Interference Capacitor Electrical Connector
    G02764000Courtesy of FORD MOTOR CO.
  15. Disconnect the knock sensor (KS) electrical connector, if equipped.
    Fig 13: Disconnecting Knock Sensor (KS) Electrical Connector
    G02764001Courtesy of FORD MOTOR CO.
  16. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 14: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G02764002Courtesy of FORD MOTOR CO.
  17. Disconnect the oil pressure switch electrical connector.
    Fig 15: Disconnecting Oil Pressure Switch Electrical Connector
    G02764003Courtesy of FORD MOTOR CO.
  18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
    19. NOTE: RH shown, LH similar.
    Fig 16: Removing Radio Interference Capacitor
    G02764004Courtesy of FORD MOTOR CO.
  19. Remove the nuts and the two radio interference capacitors.
  20. Remove the positive crankcase ventilation (PCV) valve tube from the LH valve cover and position aside.
    Fig 17: Removing Positive Crankcase Ventilation (PCV) Valve Tube
    G02764005Courtesy of FORD MOTOR CO.
  21. Remove the nut attaching the oil level indicator tube to the front of the engine.
    Fig 18: Removing Nut Attaching Oil Level Indicator Tube To Front Of Engine
    G02764006Courtesy of FORD MOTOR CO.
  22. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
    Fig 19: Removing Bolt Attaching Oil Level Indicator Tube To Rear Of Engine
    G02764007Courtesy of FORD MOTOR CO.
  23. Position the oil level indicator tube aside.
    Fig 20: Positioning Oil Level Indicator Tube Aside
    G02764008Courtesy of FORD MOTOR CO.
    24. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: The bolts are part of the valve cover and should not be removed.
    Fig 21: Removing LH Valve Cover
    G02764009Courtesy of FORD MOTOR CO.
  24. Remove the LH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
    25. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: The bolts are part of the valve cover and should not be removed.
    Fig 22: Removing RH Valve Cover
    G02764010Courtesy of FORD MOTOR CO.
  25. Remove the RH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
  26. Remove the bolt and the idler pulley.
    Fig 23: Removing Bolt And Idler Pulley
    G02764011Courtesy of FORD MOTOR CO.
  27. Remove the water pump pulley.
    1. Remove the bolts.
    2. Remove the water pump pulley.
    Fig 24: Removing Water Pump Pulley
    G02764012Courtesy of FORD MOTOR CO.
  28. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
    Fig 25: Removing Crankshaft Pulley
    G02764013Courtesy of FORD MOTOR CO.
  29. Using the special tool, remove the crankshaft front seal.
    Fig 26: Removing Crankshaft Front Seal
    G02764014Courtesy of FORD MOTOR CO.
  30. Remove the power steering pump.
    Fig 27: Removing Power Steering Pump
    G02764015Courtesy of FORD MOTOR CO.
  31. Remove the four oil pan bolts.
    Fig 28: Removing Front Four Oil Pan Bolts
    G02764016Courtesy of FORD MOTOR CO.
    32. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 29: Removing Fasteners
    G02764017Courtesy of FORD MOTOR CO.
  32. Remove the fasteners.
  33. Remove the engine front cover from the cylinder block.
    Fig 30: Removing Engine Front Cover From Cylinder Block
    G02764018Courtesy of FORD MOTOR CO.
  34. Remove the crankshaft sensor ring from the crankshaft.
    Fig 31: Removing Crankshaft Sensor Ring From Crankshaft
    G02764019Courtesy of FORD MOTOR CO.
    35. CAUTION: The caps must be marked for installation in their original location or damage to the engine may occur.
    Fig 32: Removing Six Bolts And Remove Balance Shaft Bearing Caps
    G02764020Courtesy of FORD MOTOR CO.
  35. Remove the six bolts and remove the balance shaft bearing caps.
  36. Remove the balance shaft.
    Fig 33: Removing Balance Shaft
    G02764021Courtesy of FORD MOTOR CO.
    37. CAUTION: Use care when removing the spark plugs.
    NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
  37. Remove the 10 spark plugs.
  38. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 34: Installing Special Tool Between Valve Spring Coils To Prevent Valve Stem Seal Damage
    G01537438Courtesy of FORD MOTOR CO.
    39. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
    NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
    Fig 35: Compressing Valve Spring & Removing Camshaft Roller Follower
    G02764023Courtesy of FORD MOTOR CO.
  39. Use the special tool to compress the valve springs and remove the camshaft roller followers.
  40. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 36: Positioning Crankshaft With Keyway At 12 O'Clock Position
    G02764024Courtesy of FORD MOTOR CO.
  41. 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 37: Removing Timing Chain Tensioning System
    G02764025Courtesy of FORD MOTOR CO.
  42. Remove the RH and LH timing chains and the crankshaft sprocket(s).
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain from the crankshaft sprocket.
    • Remove the LH timing chain from the camshaft sprocket.
    • Remove the LH timing chain from the crankshaft sprocket.
    Fig 38: Removing RH And LH Timing Chains And Crankshaft Sprocket(s)
    G02764026Courtesy of FORD MOTOR CO.
  43. Remove both timing chain guides.
    • Remove the bolts.
    • Remove the timing chain guides.
    Fig 39: Removing Timing Chain Guides
    G02764027Courtesy of FORD MOTOR CO.

    44. RH CYLINDER HEAD 

  44. Remove the RH exhaust manifold.
    • Remove the nuts.
    • Remove the RH exhaust manifold.
    • Remove the RH exhaust manifold gasket.
    Fig 40: Removing RH Exhaust Manifold
    G02764028Courtesy of FORD MOTOR CO.

    45. LH CYLINDER HEAD 

  45. Remove the LH exhaust manifold.
    • Remove the nuts.
    • Remove the LH exhaust manifold.
    • Remove the LH exhaust manifold gasket.
    Fig 41: Removing LH Exhaust Manifold
    G02764029Courtesy of FORD MOTOR CO.

    46. BOTH CYLINDER HEADS 

  46. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  47. Install the special tools on both ends of the cylinder head.
    Fig 42: Installing Special Tools On Both Ends Of Cylinder Head
    G02764030Courtesy of FORD MOTOR CO.
    48. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 43: Removing Hydraulic Lash Adjusters
    G02764031Courtesy of FORD MOTOR CO.
  48. Remove the hydraulic lash adjusters.

    49. RH CYLINDER HEAD 

    CAUTION: 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.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield and cannot be reused.
    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 which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: RH shown, LH similar.
    Fig 44: Removing RH Cylinder Head
    G02764032Courtesy of FORD MOTOR CO.
  49. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.

    50. LH CYLINDER HEAD 

    CAUTION: 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.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield and cannot be reused.
    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 which make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: RH shown, LH similar.
    Fig 45: Removing Cylinder Head
    G02764033Courtesy of FORD MOTOR CO.
  50. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.

    51. BOTH 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 which 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 surfaces.
  51. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
    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 surface is normal.
    52. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
    NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machine edge must be flat with 0.010 mm (0.0004 in) from end to end.
    NOTE: LH is shown, RH is similar.
    Fig 46: Inspecting Cylinder Head
    G02764034Courtesy of FORD MOTOR CO.
  52. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
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