Cylinder Head: Removal

Both sides 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
4. Remove the intake manifold. For additional information, refer to Intake Manifold .
5. Remove the hydraulic lash adjusters. For additional information, refer to Hydraulic Lash Adjuster .
6. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
Fig 1: Rotating Accessory Drive Belt Tensioner
Courtesy of FORD MOTOR CO.

RH side 

7. Remove the 2 coolant tube bracket bolts.
Fig 2: Locating Coolant Tube Bracket Bolts
Courtesy of FORD MOTOR CO.
8. Disconnect the generator electrical connector, remove the nut and detach the B+ terminal.
   • Detach the pin-type retainer.
Fig 3: Locating Generator Electrical Connections Pin-Type Retainer
Courtesy of FORD MOTOR CO.
9. Remove the bolt and the accessory drive belt tensioner.
Fig 4: Locating Belt Tensioner Bolt
Courtesy of FORD MOTOR CO.
10. Remove the nut, the 2 bolts and the generator mounting bracket assembly.
Fig 5: Locating Generator Mounting Bracket Assembly Bolts
Courtesy of FORD MOTOR CO.
11. Disconnect the heater hose from the thermostat housing.
Fig 6: Locating Heater Hose From Thermostat Housing
Courtesy of FORD MOTOR CO.
12. Disconnect the upper radiator hose.
Fig 7: Locating Upper Radiator Hose Clamp
Courtesy of FORD MOTOR CO.
13. Position the coolant bypass hose clamp aside.
Fig 8: Locating Coolant Bypass Hose Clamp
Courtesy of FORD MOTOR CO.
14. Remove the 3 bolts and the thermostat housing.
    • Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
Fig 9: Locating Thermostat Housing
Courtesy of FORD MOTOR CO.

LH side 

15. Remove the bolt and the oil level indicator tube.
Fig 10: Locating Oil Level Indicator Tube And Bolt
Courtesy of FORD MOTOR CO.
16. Remove the stud bolt and detach the ground strap.
    • Position the ground strap aside.
Fig 11: Locating Ground Strap Stud Bolt
Courtesy of FORD MOTOR CO.
17. Remove the bolt and detach the power steering supply hose bracket from the Front End Accessory Drive (FEAD) bracket.
Fig 12: Locating Power Steering Supply Hose Bracket Bolt
Courtesy of FORD MOTOR CO.
18. Remove the bolt and detach the Power Steering Pressure (PSP) tube bracket from the crossmember.
Fig 13: Locating PSP Tube Bracket Bolt
Courtesy of FORD MOTOR CO.
19. Remove the 3 bolts and the power steering pump pulley.
Fig 14: Locating Power Steering Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
20. Remove the 3 bolts and position the power steering pump aside.
Fig 15: Locating Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
21. Remove the 3 bolts, the nut and position the FEAD bracket and A/C compressor aside.
Fig 16: Locating FEAD Bracket And A/C Compressor Bracket Bolts
Courtesy of FORD MOTOR CO.
22. Remove the bolt and detach the starter motor wiring retainer bracket.
Fig 17: Locating Starter Motor Wiring Retainer Bracket Bolt
Courtesy of FORD MOTOR CO.
23. Remove the ground strap bolt and detach the wiring harness retainer from the backside of the cylinder head.
Fig 18: Locating Ground Strap Bolt
Courtesy of FORD MOTOR CO.

Both sides 

NOTE: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
24. Using the Spark Plug Wire Remover, disconnect the 6 spark plug wires from the spark plugs.
Fig 19: Pulling Spark Plug Wire Off Spark Plug
Courtesy of FORD MOTOR CO.
25. Remove the 4 bolts and the fuel rail and injectors.
Fig 20: Locating Fuel Rail And Injectors Bolts
Courtesy of FORD MOTOR CO.
26. Separate the 6 fuel injectors from the fuel rail and discard the O-ring seals.
NOTE: LH side shown, RH side similar.
27. Remove the 4 catalytic converter-to-manifold nuts.
    • Discard the nuts.
Fig 21: Locating Catalytic Converter-To-Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, RH side similar.
28. Remove the 12 nuts and the exhaust manifolds and gaskets.
    • Discard the nuts and gaskets.
Fig 22: Locating Exhaust Manifolds, Gaskets & Nuts
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, RH side similar.
29. Remove and discard the 12 exhaust manifold studs.
Fig 23: Locating Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.

RH side 

30. Remove the RH side hydraulic chain tensioner.
    • Remove and discard the washer.
Fig 24: Locating RH Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
31. Install the Camshaft Sprocket Holding Tool and Adapter.
    • Tighten the top clamp bolts to 10 Nm (89 lb-in).
Fig 25: Locating Clamp Bolts & Special Tools (303-564, 303-578)
Courtesy of FORD MOTOR CO.
NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt.
32. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, remove the RH camshaft bolt.
Fig 26: Identifying Special Tool (303-575)
Courtesy of FORD MOTOR CO.
33. Remove the RH side cassette bolt.
Fig 27: Locating RH Side Cassette Bolt
Courtesy of FORD MOTOR CO.
NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
34. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
Fig 28: Locating RH Camshaft Sprocket
Courtesy of FORD MOTOR CO.

LH side 

35. Remove the LH side hydraulic chain tensioner.
    • Remove and discard the washer.
Fig 29: Locating Camshaft Tensioner
Courtesy of FORD MOTOR CO.
36. Install the Camshaft Sprocket Holding Tool and Adapter.
    • Tighten to 10 Nm (89 lb-in).
Fig 30: Identifying Special Holding Tool
Courtesy of FORD MOTOR CO.
37. Remove the LH side camshaft sprocket bolt.
Fig 31: Locating LH Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
38. Remove the LH side cassette bolt.
Fig 32: Locating Chain Guide Bolt
Courtesy of FORD MOTOR CO.
NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
39. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
Fig 33: Locating Cassette And Timing Chain
Courtesy of FORD MOTOR CO.

Both sides 

NOTE: To avoid damage to the timing chain cassette, an assistant will be required to help lift the cylinder head from the vehicle.
NOTE: On the RH side, when lifting the cylinder head, be careful to avoid contacting the A/C tube.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
40. Remove the cylinder heads.
    • Remove the cylinder head bolts in the sequence shown. Discard all the bolts.
    • Remove and discard the head gaskets.
Fig 34: Identifying Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
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 and 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.
41. Clean the cylinder head-to-cylinder block mating surface 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 remove 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 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.
42. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .