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Cylinder Head

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SPECIAL TOOL DESCRIPTION

G06061933
 3 Jaw Puller
303-D121  or equivalent
G06094613
 Adapter Set, Step Plate
205-DS011  or equivalent
G06126494
 Lifting Bracket, Engine
303-F047  (014-00073) or equivalent
G06061943
 Remover, Oil Seal
303-409  (T92C-6700-CH)
G06518201
 Support Brackets, Engine
303-1507  or equivalent
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-B		 -
Motorcraft® Silicone Gasket Remover
ZC-30-A		 -
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTE: The flexplate and spacer plate must be removed before mounting the engine on the engine stand.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY  procedure.

All cylinder heads 

  1. Remove the engine. For additional information, refer to ENGINE .
  2. Remove the 8 bolts and the flexplate.
    • Discard the 8 flexplate bolts.
      Fig 1: Locating Flexplate Bolts
      G06518359Courtesy of FORD MOTOR CO.
  3. Remove the spacer plate.
    Fig 2: Locating Spacer Plate
    G06518360Courtesy of FORD MOTOR CO.
  4. Disconnect the electrical connector and remove the bolt and the Crankshaft Position (CKP) sensor.
    Fig 3: Locating Electrical Connector, Crankshaft Position Sensor And Mounting Bolt
    G09542206Courtesy of FORD MOTOR CO.
  5. Mount the engine on a work stand.
  6. Remove the Engine Lifting Brackets.
    Fig 4: Removing Engine Lifting Brackets
    G06518354Courtesy of FORD MOTOR CO.
  7. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    Fig 5: Locating Engine Oil Pressure Switch Electrical Connector
    G06518363Courtesy of FORD MOTOR CO.
  8. Disconnect the LH Variable Camshaft Timing (VCT) variable force solenoid electrical connector and the 2 wiring harness retainers.
    Fig 6: Locating VCT Variable Force Solenoid Electrical Connector And Wiring Harness Retainers (LH)
    G06518364Courtesy of FORD MOTOR CO.
  9. Disconnect the 3 engine wiring harness position retainers from the LH valve cover.
    Fig 7: Locating Engine Wiring Harness Position Retainers From Valve Cover (LH)
    G06518365Courtesy of FORD MOTOR CO.
  10. Disconnect the wiring harness retainer, the Knock Sensor (KS) and Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 8: Locating Wiring Harness Retainer, Knock Sensor And Cylinder Head Temperature Sensor Electrical Connector
    G06518366Courtesy of FORD MOTOR CO.
  11. Disconnect the LH and RH Camshaft Position (CMP) sensor electrical connectors.
    Fig 9: Locating Camshaft Position Sensor Electrical Connectors (LH And RH)
    G06518367Courtesy of FORD MOTOR CO.
  12. Remove the nut and the wiring harness ground cable.
    Fig 10: Locating Wiring Harness Ground Cable Nut
    G06518133Courtesy of FORD MOTOR CO.
  13. Remove the nut and the radio interference capacitor.
    Fig 11: Locating Radio Ignition Interference Capacitor And Nut
    G06518134Courtesy of FORD MOTOR CO.
  14. Disconnect the RH VCT variable force solenoid electrical connector and the 2 wiring harness retainers.
    Fig 12: Locating VCT Variable Force Solenoid Electrical Connector And Wiring Harness Retainers (RH)
    G06518370Courtesy of FORD MOTOR CO.
  15. Disconnect the 3 engine wiring harness position retainers from the RH valve cover and remove the engine wiring harness.
    Fig 13: Locating Engine Wiring Harness Position Retainers
    G06518371Courtesy of FORD MOTOR CO.
  16. NOTE: RH shown in illustration, LH similar.

    Disconnect the 8 ignition wires from the valve cover retainers and the lower spark plugs.

    Fig 14: Locating Ignition Wires From Valve Cover Retainers And Lower Spark Plugs
    G06518372Courtesy of FORD MOTOR CO.
  17. Remove the 2 bolts and the LH and RH CMP sensors.
    Fig 15: Locating CMP Sensors Bolts (LH And RH)
    G06518373Courtesy of FORD MOTOR CO.
  18. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 16: Locating Oil Level Indicator Tube And Bolt
      G06518374Courtesy of FORD MOTOR CO.
  19. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: Remove the valve cover carefully, or the Variable Camshaft Timing (VCT) variable force solenoid may be damaged.
    NOTE: The bolts are part of the valve cover and should not be removed.

    Loosen the 10 bolts and remove the LH 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 valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
      Fig 17: Locating Valve Cover And Bolts (LH)
      G06518375Courtesy of FORD MOTOR CO.
  20. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: Remove the valve cover carefully, or the Variable Camshaft Timing (VCT) variable force solenoid may be damaged.
    NOTE: The bolts are part of the valve cover and should not be removed.

    Loosen the 10 bolts and remove the RH 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 valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
      Fig 18: Locating Valve Cover Gasket (RH)
      G06518376Courtesy of FORD MOTOR CO.
  21. Remove the 6 bolts, the coolant pump pulley and the 2 accessory drive belt idler pulleys.
    Fig 19: Locating Coolant Pump Pulley, Accessory Drive Belt Idler Pulleys And Bolts
    G06518377Courtesy of FORD MOTOR CO.
  22. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 20: Locating Accessory Drive Belt Tensioner Bolts
    G06126553Courtesy of FORD MOTOR CO.
  23. Using the 3 Jaw Puller and Step Plate, remove the crankshaft pulley.
    Fig 21: Removing Crankshaft Pulley
    G07404433Courtesy of FORD MOTOR CO.
  24. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    Using the Oil Seal Remover, remove the crankshaft front oil seal.

    G08339345
  25. Remove the front 4 oil pan bolts.
    Fig 22: Locating Front Oil Pan Bolts
    G06126556Courtesy of FORD MOTOR CO.
  26. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.

    Remove the 17 bolts and the 3 studs.

    Fig 23: Locating Engine Front Cover Studs And Bolts
    G06518382Courtesy of FORD MOTOR CO.
  27. Remove the engine front cover from the front cover-to-cylinder block dowel.
    • Remove and discard the engine front cover gaskets.
      Fig 24: Removing Engine Front Cover Gaskets
      G06518141Courtesy of FORD MOTOR CO.
  28. Rotate the engine clockwise until the No. 1 intake valve is open.
  29. Remove the 10 bolts and the LH intake rocker arm shaft assembly.
    Fig 25: Locating Engine Wiring Harness Position Retainers
    G06518384Courtesy of FORD MOTOR CO.
  30. Rotate the engine clockwise until the No. 1 exhaust valve is open.
  31. Remove the 10 bolts and the LH exhaust rocker arm shaft assembly.
    Fig 26: Locating Exhaust Rocker Arm Shaft Assembly And Bolts (LH)
    G06518385Courtesy of FORD MOTOR CO.
  32. Rotate the engine clockwise until the No. 1 intake valve is closed.
  33. Remove the 10 bolts and the RH intake rocker arm shaft assembly.
    Fig 27: Locating Intake Rocker Arm Shaft Assembly And Bolts (RH)
    G06518386Courtesy of FORD MOTOR CO.
  34. Rotate the engine clockwise until the No. 1 exhaust valve is closed.
  35. Remove the 10 bolts and the RH exhaust rocker arm shaft assembly.
    Fig 28: Locating Exhaust Rocker Arm Shaft Assembly And Bolts (RH)
    G06518387Courtesy of FORD MOTOR CO.
  36. Position the crankshaft keyway at the 11 o'clock position.
    Fig 29: Locating Crankshaft Keyway
    G06518157Courtesy of FORD MOTOR CO.
  37. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
    Fig 30: Locating Timing Chain Tensioner And Tensioner Arm Bolts (RH)
    G06518158Courtesy of FORD MOTOR CO.
  38. Remove the bolt and the RH timing chain guide.
    Fig 31: Locating Timing Chain Guide And Bolt (RH)
    G06518159Courtesy of FORD MOTOR CO.
  39. Remove the RH timing chain.
    Fig 32: Locating Timing Chain (RH)
    G06518160Courtesy of FORD MOTOR CO.
  40. Remove the 2 bolts and the LH timing chain tensioner.
    Fig 33: Locating Timing Chain Tensioner And Bolts (LH)
    G06518161Courtesy of FORD MOTOR CO.
  41. Remove the LH timing chain tensioner arm.
    Fig 34: Locating Timing Chain Tensioner Arm (LH)
    G06518162Courtesy of FORD MOTOR CO.
  42. Remove the bolt and the LH timing chain guide.
    Fig 35: Locating Timing Chain Guide And Bolt (LH)
    G06518163Courtesy of FORD MOTOR CO.
  43. Remove the LH timing chain.
    Fig 36: Locating Timing Chain (LH)
    G06518164Courtesy of FORD MOTOR CO.

    LH cylinder head 

  44. Remove the 2 bolts and the LH exhaust manifold heat shield.
    Fig 37: Locating Exhaust Shield And Bolts
    G06518210Courtesy of FORD MOTOR CO.
  45. Remove the 8 nuts, the 8 studs, the LH exhaust manifold and gaskets.
    • Discard the 8 nuts and the 8 studs.
    • Discard the 2 gasket.
    • Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
      Fig 38: Locating Exhaust Manifold Bolt
      G06126576Courtesy of FORD MOTOR CO.
  46. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage may result if a warm or hot cylinder head is removed.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface, or the cylinder head may be damaged.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

    Remove the 11 bolts and the LH cylinder head.

    • Discard the cylinder head gasket.
    • Discard the 11 cylinder head bolts.
      Fig 39: Locating Cylinder Head Bolts
      G06518398Courtesy of FORD MOTOR CO.

    RH cylinder head 

  47. Remove the 2 bolts and the RH exhaust manifold heat shield.
    Fig 40: Locating Exhaust Manifold Heat Shield Bolts (RH)
    G09542244Courtesy of FORD MOTOR CO.
  48. Remove the 8 nuts, the 8 studs, the RH exhaust manifold and gaskets.
    • Discard the 8 nuts and the 8 studs.
    • Discard the 2 gasket.
    • Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
      Fig 41: Locating Exhaust Manifold And Gaskets Mounting Bolt (RH)
      G09390291Courtesy of FORD MOTOR CO.
  49. Remove the nut and the ground strap.
    Fig 42: Locating Nut And Ground Strap
    G06126586Courtesy of FORD MOTOR CO.
  50. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage may result if a warm or hot cylinder head is removed.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface, or the cylinder head may be damaged.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

    Remove the 10 bolts and the RH cylinder head.

    • Discard the cylinder head gasket.
    • Discard the 11 cylinder head bolts.
      Fig 43: Locating Cylinder Head Bolts
      G06518402Courtesy of FORD MOTOR CO.

    All cylinder heads 

  51. 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 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.

    Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.

    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.
  52. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
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