Cylinder Head

Illustration	Tool Name	Tool Number
	Compressor, Valve Spring	303-567 (T97P-6565-AH)
	Engine Lift Bracket Set	303-DS086 (D93P-6001-A)
	Modular Engine Lift Bracket	303-F047 (014-00073) or equivalent
	Remover, Crankshaft Front Seal	303-107 (T74P-6700-A)
	Remover, Crankshaft Vibration Damper	303-009 (T58P-6316-D)
	Remover/Installer, Cylinder Head	303-572 (T97T-6565-AH)
	Spacer, Valve Spring	303-382 (T91P-6565-AH)

Both cylinder heads 

1. Remove the engine. For additional information, refer to Engine .
2. Remove the 8 bolts and the flexplate.
Fig 1: Flexplate Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Use care when lowering the engine, to prevent damage to the oil pan.
3. Lower the engine onto wooden blocks.
4. Remove the special tool.
Fig 2: Identifying Special Tool (303-F047)
Courtesy of FORD MOTOR CO.
5. Install the special tool.
Fig 3: Special Tool (303-D087)
Courtesy of FORD MOTOR CO.
6. Install the special tool.
Fig 4: Special Tool (303-D088)
Courtesy of FORD MOTOR CO.
7. Mount the engine on a suitable work stand.
8. Remove the 4 bolts and the RH engine support insulator.
Fig 5: Right Engine Support Insulator Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
9. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
Fig 6: Locating Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
10. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
Fig 7: Locating LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
11. Disconnect the camshaft position (CMP) electrical connector.
Fig 8: Locating Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
12. Disconnect the RH radio frequency interference capacitor electrical connector.
Fig 9: Locating RH Radio Ignition Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
13. Disconnect the knock sensor (KS) electrical connector, if equipped.
Fig 10: Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
14. Disconnect the crankshaft position (CKP) sensor electrical connector.
Fig 11: Locating CKP Sensor Electrical Connector And Harness Retainer
Courtesy of FORD MOTOR CO.
15. Disconnect the engine oil pressure (EOP) switch electrical connector.
Fig 12: Locating Oil Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
16. Disconnect all of the engine control sensor wiring harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
NOTE: RH shown, LH similar.
17. Remove the 2 nuts and the 2 radio frequency interference capacitors.
Fig 13: Radio Interference Capacitor And Retaining Nut
Courtesy of FORD MOTOR CO.
18. Disconnect the quick connect coupling and remove the PCV valve tube from the LH valve cover. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
Fig 14: Identifying Positive Crankcase Ventilation (PCV) Valve Tube
Courtesy of FORD MOTOR CO.
19. Remove the nut attaching the oil level indicator tube to the front of the engine.
Fig 15: Oil Level Indicator Tube Nut
Courtesy of FORD MOTOR CO.
20. Remove the bolt attaching the oil level indicator tube to the LH cylinder head.
Fig 16: Oil Level Indicator Tube Bolt
Courtesy of FORD MOTOR CO.
21. Position the oil level indicator tube aside.
Fig 17: Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
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 fasteners are part of the valve cover and should not be removed.
22. Remove the LH valve cover.
    • Fully loosen the fasteners 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.
    • Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
Fig 18: Identifying Valve Cover Fasteners
Courtesy of FORD MOTOR CO.
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 fasteners are part of the valve cover and should not be removed.
23. Remove the RH valve cover.
    • Fully loosen the fasteners 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.
    • Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
Fig 19: Identifying Valve Cover Bolts
Courtesy of FORD MOTOR CO.
24. Remove the bolt and the idler pulley.
Fig 20: Accessory Drive Belt Idler Pulley And Retaining Bolt
Courtesy of FORD MOTOR CO.
25. Remove the 4 bolts and the coolant pump pulley.
Fig 21: Identifying Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
26. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
27. Using the special tool, remove the crankshaft pulley.
Fig 22: Removing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.
28. Using the special tool, remove and discard the crankshaft front seal.
Fig 23: Removing Crankshaft Front Seal Using Special Tool
Courtesy of FORD MOTOR CO.
29. Remove the 3 bolts and the power steering pump.
Fig 24: Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
30. Remove the 4 front oil pan bolts.
Fig 25: Front Oil Pan Bolts
Courtesy of FORD MOTOR CO.
NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
31. Remove the fasteners.
Fig 26: Front Cover Bolts
Courtesy of FORD MOTOR CO.
32. Remove the engine front cover from the cylinder block.
Fig 27: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.
33. Remove the crankshaft sensor ring from the crankshaft.
Fig 28: View Of Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
CAUTION: The balance shaft bearing caps must be installed in their original locations. Record the balance shaft bearing cap locations. Failure to follow these instructions may result in engine damage.
34. Remove the 6 bolts and remove the balance shaft bearing caps.
Fig 29: Balance Shaft Caps & Bolts
Courtesy of FORD MOTOR CO.
35. Remove the balance shaft.
Fig 30: Balance Shaft
Courtesy of FORD MOTOR CO.
36. Remove the 10 spark plugs. For additional information, refer to ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V) article or ENGINE IGNITION - 6.8L article.
NOTE: Camshaft roller follower is removed for clarity.
37. Install the special tool between the valve spring coils to prevent valve stem seal damage.
Fig 31: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
CAUTION: The camshaft roller followers must be installed in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head .
NOTE: It may be necessary to push the valve down while compressing the spring.
NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
38. Use the special tool to compress the valve springs, and remove all of the camshaft roller followers.
Fig 32: Compressing Valve Springs Using Special Tool (303-567)
Courtesy of FORD MOTOR CO.
39. Position the crankshaft with the keyway at the 12 o'clock position.
Fig 33: Crankshaft With Keyway At 12 O'clock Position
Courtesy of FORD MOTOR CO.
CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Failure to follow these instructions may result in engine damage.
40. Remove the timing chain tensioning system from both timing chains.
    1. Remove the 4 bolts.
    2. Remove the 2 timing chain tensioners.
    3. Remove the 2 timing chain tensioner arms.
Fig 34: Identifying Timing Chain Tensioning System
Courtesy of FORD MOTOR CO.
41. Remove the timing chains and crankshaft sprocket.
Fig 35: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
Courtesy of FORD MOTOR CO.
42. Remove the 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 36: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.

RH cylinder head 

43. Remove the RH exhaust manifold.
    • Remove and discard the 10 nuts.
    • Remove the RH exhaust manifold.
    • Remove and discard the exhaust manifold gaskets.
Fig 37: Removing RH Exhaust Manifold
Courtesy of FORD MOTOR CO.
44. Remove and discard the 10 RH exhaust manifold studs.
Fig 38: Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
45. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.

LH cylinder head 

46. Remove the LH exhaust manifold.
    • Remove and discard the 10 nuts.
    • Remove the LH exhaust manifold.
    • Remove and discard the LH exhaust manifold gaskets.
Fig 39: Removing LH Exhaust Manifold
Courtesy of FORD MOTOR CO.
47. Remove and discard the 10 LH exhaust manifold studs.
Fig 40: Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
48. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.

Both cylinder heads 

49. Install the special tools on both ends of the cylinder head being serviced.
Fig 41: Identifying Special Tool (303-572)
Courtesy of FORD MOTOR CO.
CAUTION: The hydraulic lash adjusters must be installed in their original locations. Record the hydraulic lash adjuster locations. Failure to follow these instructions may result in engine damage.
50. Remove the hydraulic lash adjusters.
Fig 42: Locating Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.
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. Failure to follow these instructions may result in engine damage.
CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. Failure to follow these instructions may result in engine damage.
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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow these instructions may result in engine damage.
NOTE: LH shown, RH similar.
51. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
Fig 43: Removing Head
Courtesy of FORD MOTOR CO.
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. Failure to follow these instructions may result in engine damage.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
52. 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 surfaces is normal.
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 shown, RH similar.
53. 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).
Fig 44: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
Courtesy of FORD MOTOR CO.