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Cylinder Head

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Special Tools

Illustration Tool Name Tool Number
GF0000311Courtesy of FORD MOTOR CO.
 3-Jaw Puller 303-D121
GF0000329Courtesy of FORD MOTOR CO.
 Compressor, Valve Spring 303-1039
GF0000330Courtesy of FORD MOTOR CO.
 Locking Tool, Camshaft Phaser Sprocket 303-1046
GF0000339Courtesy of FORD MOTOR CO.
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
GF0000344Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Front Seal 303-107 (T74P-6700-A)
GF0000345Courtesy of FORD MOTOR CO.
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
Material

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

All cylinder heads 

  1. Remove the engine. For additional information, refer to Engine .
  2. Mount the engine on a suitable work stand.
  3. Remove the special tool.
    4. Fig 1: Identifying Special Tool (303-F047)
    G03920205Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  4. Disconnect the RH and LH camshaft position (CMP) sensor electrical connectors.
    5. Fig 2: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  5. Disconnect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.
    6. Fig 3: Locating Camshaft Timing (VCT) Solenoid Electrical Connectors
    G03920220Courtesy of FORD MOTOR CO.
  6. Detach the engine wiring harness pin-type retainers.
    7. Fig 4: Locating Engine Wiring Harness Pin-Type Retainers
    GF0015227Courtesy of FORD MOTOR CO.
  7. Remove the nut and the RH radio ignition interference capacitor.
    8. Fig 5: Identifying Nut & RH Radio Ignition Interference Capacitor
    GF0015228Courtesy of FORD MOTOR CO.
    NOTE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating it from the tube.
  8. Remove the PCV tubes from the RH and LH valve covers.
    • Disconnect the quick connect fittings.
      • Push the connector toward the valve cover to release pressure.
      • Push the release tab clockwise.
      • Disconnect the quick connect fitting.
    9. Fig 6: Locating Positive Crankcase Ventilation Tubes
    GF0015229Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  9. Disconnect the 4 RH and 4 LH ignition coil electrical connectors.
    10. Fig 7: Locating Ignition Coil Electrical Connectors
    G03920223Courtesy of FORD MOTOR CO.
  10. Disconnect the 3 engine wiring harness retainers from the RH valve cover studs.
    11. Fig 8: Disconnecting Engine Wiring Harness Retainers From RH Valve Cover Studs
    GF0000346Courtesy of FORD MOTOR CO.
  11. Disconnect the 2 engine wiring harness retainers from the LH valve cover studs.
    12. Fig 9: Locating Engine Wiring Harness Retainers
    GF0015230Courtesy of FORD MOTOR CO.
  12. Detach the engine wiring harness pin-type retainers.
    13. Fig 10: Locating Engine Wiring Harness Pin-Type Retainers
    GF0000347Courtesy of FORD MOTOR CO.
  13. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    14. Fig 11: Locating CHT Sensor Electrical Connector
    GF0015231Courtesy of FORD MOTOR CO.
  14. Detach the CHT sensor jumper harness electrical connector pin-type retainer.
    15. Fig 12: Identifying Cylinder Head Temperature (CHT) Sensor Jumper Harness Electrical Connector
    GF0015232Courtesy of FORD MOTOR CO.
  15. Disconnect the knock sensor (KS) electrical connector and pin-type retainer.
    16. Fig 13: Locating Knock Sensor (KS) Electrical Connector And Pin-Type Retainer
    GF0015233Courtesy of FORD MOTOR CO.
  16. Disconnect the LH heated oxygen sensor (HO2S) electrical connector.
    • Detach the engine wiring harness retainer from the stud bolt.
    17. Fig 14: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0015197Courtesy of FORD MOTOR CO.
  17. Disconnect the engine oil pressure (EOP) switch electrical connector.
    18. Fig 15: Locating Engine Oil Pressure Sensor Electrical Connector
    GF0015234Courtesy of FORD MOTOR CO.
  18. Remove the engine wiring harness from the engine.
  19. Remove and discard the oil filter.
  20. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
    21. Fig 16: Locating Oil Level Indicator Tube Bolt
    GF0002790Courtesy of FORD MOTOR CO.
  21. Remove the bolt and the RH CMP sensor.
    22. Fig 17: Locating RH CMP Sensor And Bolt
    GF0015235Courtesy of FORD MOTOR CO.
  22. Remove the bolt and the LH CMP sensor.
    23. Fig 18: Locating Camshaft Position (CMP) Sensor And Bolt
    GF0015236Courtesy of FORD MOTOR CO.
  23. Remove the bolt and the CKP sensor.
    24. Fig 19: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  24. Remove the 8 bolts and the 8 ignition coils.
    25. Fig 20: Identifying Ignition Coils And Bolts
    G03920226Courtesy 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.
    CAUTION: When removing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
    NOTE: The bolts are part of the valve cover and should not be removed.
    NOTE: LH shown, RH similar.
  25. Loosen the 29 bolts and remove the valve covers.
    • 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. Fig 21: Locating Valve Cover Bolts
    GF0002791Courtesy of FORD MOTOR CO.
  26. Remove the 5 bolts, the coolant pump pulley and the RH side accessory drive belt idler pulley.
    27. Fig 22: Locating Accessory Drive Belt Idler Pulley And Bolts
    GF0015237Courtesy of FORD MOTOR CO.
  27. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    28. Fig 23: Removing Crankshaft Pulley Using Special Tool (303-D121)
    GF0000312Courtesy of FORD MOTOR CO.
  28. Using the special tool, remove the crankshaft seal.
    29. Fig 24: Removing Crankshaft Front Seal Using Special Tool (303-107)
    G03919889Courtesy of FORD MOTOR CO.
  29. Remove the 4 oil pan-to-engine front cover bolts.
    30. Fig 25: Front Oil Pan Bolts
    GF0000348Courtesy of FORD MOTOR CO.
    NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.
  30. Remove the engine front cover fasteners.
    31. Fig 26: Locating Engine Front Cover Fasteners
    GF0015189Courtesy of FORD MOTOR CO.
  31. Remove the engine front cover from the cylinder block.
    32. Fig 27: Removing Engine Front Cover From Cylinder Block
    GF0000349Courtesy of FORD MOTOR CO.
  32. Remove the crankshaft sensor ring from the crankshaft.
    33. Fig 28: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
  33. Position the crankshaft keyway at the 12 o'clock position.
    34. Fig 29: Positioning Crankshaft Keyway At 12 O'Clock Position
    G03919943Courtesy of FORD MOTOR CO.
    NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to the 12 o'clock position.
  34. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake lobes and the exhaust lobe on the No. 1 cylinder.
    35. Fig 30: Identifying Camshaft Lobe Position
    G03919944Courtesy of FORD MOTOR CO.
    CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  35. Remove only the 3 roller followers shown in the illustration from the RH cylinder head.
    36. Fig 31: Identifying RH Cylinder Head Camshaft Roller Followers And Bolts
    G03919945Courtesy of FORD MOTOR CO.
    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.
    NOTE: It may be necessary to push the valve down while compressing the spring.
  36. Using the special tool, remove the 3 roller followers designated in the previous step from the RH cylinder head.
    37. Fig 32: Identifying Special Tool (303-1039) For Removing/Installing Camshaft Roller Followers
    G03919946Courtesy of FORD MOTOR CO.
    CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  37. Remove only the 3 roller followers shown in the illustration from the LH cylinder head.
    38. Fig 33: Locating LH Cylinder Head Camshaft Roller Followers And Bolts
    G03919947Courtesy of FORD MOTOR CO.
    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.
    NOTE: It may be necessary to push the valve down while compressing the spring.
  38. Using the special tool, remove the 3 roller followers designated in the previous step from the LH cylinder head.
    39. Fig 34: Compressing Spring Using Special Tool (303-1039)
    G03919948Courtesy of FORD MOTOR CO.
    CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.
  39. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    40. Fig 35: Crankshaft Positioned With Keyway At 6 O'clock Position
    G03919949Courtesy of FORD MOTOR CO.
  40. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
    41. Fig 36: Identifying LH Timing Chain Tensioner & Tensioner Arm
    G03919950Courtesy of FORD MOTOR CO.
  41. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
    42. Fig 37: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
    G03919951Courtesy of FORD MOTOR CO.
  42. Remove the RH and LH timing chains and the crankshaft sprocket.
    • 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 and crankshaft sprocket.
    43. Fig 38: Identifying RH/LH Timing Chains
    G03919952Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  43. Remove the LH and RH timing chain guides.
    • Remove the 2 bolts.
    • Remove both timing chain guides.
    44. Fig 39: Identifying Timing Chain Guide And Mounting Bolts
    G03919953Courtesy of FORD MOTOR CO.
    CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
  44. Using the special tool, remove the bolt and the RH camshaft phaser sprocket assembly.
    • Discard the camshaft phaser sprocket bolt.
    45. Fig 40: Identifying VCT Phaser Sprocket Bolt And Holder Tool
    G03919954Courtesy of FORD MOTOR CO.
    CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
  45. Using the special tool, remove the bolt and the LH camshaft phaser sprocket assembly.
    • Discard the camshaft phaser sprocket bolt.
    46. Fig 41: Identifying Special Sprocket Phaser Tool
    G03919955Courtesy of FORD MOTOR CO.
    CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
  46. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
    47. Fig 42: Removing Camshaft Front Bearing Cap Bolts
    GF0005526Courtesy of FORD MOTOR CO.
    CAUTION: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.
  47. Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.
    48. Fig 43: Removing Camshaft Bearing Caps Bolts In Sequence
    GF0005527Courtesy of FORD MOTOR CO.
  48. Clean and inspect the RH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
    49. Fig 44: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
    G03919957Courtesy of FORD MOTOR CO.
  49. Remove the RH camshaft.
    50. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
  50. Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.
    51. Fig 45: Removing Camshaft Front Bearing Cap Bolts
    GF0005526Courtesy of FORD MOTOR CO.
    CAUTION: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.
  51. Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.
    52. Fig 46: Removing Camshaft Bearing Caps Bolts In Sequence
    GF0005527Courtesy of FORD MOTOR CO.
  52. Clean and inspect the LH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
    53. Fig 47: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
    G03919957Courtesy of FORD MOTOR CO.
  53. Remove the LH camshaft.
    54. CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  54. Remove all of the remaining roller followers from the cylinder heads.

    55. LH cylinder head 

    CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  55. Remove the hydraulic lash adjusters from the LH cylinder head.
  56. Install the special tool onto the LH cylinder head.
    57. Fig 48: Identifying Special Tool (303-572) LH Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  57. Remove the 8 nuts and the LH exhaust manifold.
    • Discard the nuts and gasket.
    58. Fig 49: Locating LH Exhaust Manifold Nuts And Studs
    GF0002792Courtesy of FORD MOTOR CO.
  58. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  59. Remove and discard the 8 LH exhaust manifold studs.
  60. Remove the nut and ground strap from the stud bolt.
    61. Fig 50: Locating Ground Strap And Nut On Stud Bolt
    GF0015238Courtesy of FORD MOTOR CO.

    RH cylinder head 

    CAUTION: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  61. Remove the hydraulic lash adjusters from the RH cylinder heads.
  62. Install the special tool onto the RH cylinder head.
    63. Fig 51: Identifying Special Tool (303-572) RH Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
  63. Remove the 8 nuts and the RH exhaust manifold.
    • Discard the nuts and gasket.
    64. Fig 52: Removing Nuts And RH Exhaust Manifold
    GF0015239Courtesy of FORD MOTOR CO.
  64. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  65. Remove and discard the 8 RH exhaust manifold studs.
  66. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seals.
    67. Fig 53: Locating Coolant Tube Stud Bolt
    GF0015240Courtesy of FORD MOTOR CO.

    All cylinder heads 

    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 must be installed. They are tighten-to-yield designed 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 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.
    NOTE: RH shown, LH similar.
  67. Remove the 20 bolts and the cylinder heads.
    • Discard the cylinder head gaskets.
    • Discard the cylinder head bolts.
    68. Fig 54: Identifying Cylinder Head Gasket And Bolts
    GF0000350Courtesy 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.
    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.
  68. 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.
    69. 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 within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
    NOTE: LH shown, RH similar.
  69. Support the cylinder heads 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 heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches longer than 0.0254 mm (0.001 in).
    70. Fig 55: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
    G03885653Courtesy of FORD MOTOR CO.
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