Cylinder Head
Special Tool(s) / General Equipment
| 100-010 Remover, O-Ring Seal | |
|---|---|
| 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F |
|
| 303-1310 Holding Wrench, Crankshaft | |
| 303-1587 Timing Tool, Crankshaft | |
| 303-679A Remover/Installer, Engine Front Cover Inspection Plate | |
| Floor Crane | |
| Mounting Stand | |
| Plastic Scraper | |
| 2 mm Punch | |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft® Metal Surface Prep Wipes ZC-31-B | - |
| Motorcraft® Metal Brake Parts Cleaner PM-4-A, PM-4-B | - |
- 1.
- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Remove the bolts and the flexplate.
- Discard the bolts.
- 12.
Disconnect the wire harness retainers and electrical connectors. Disconnect the hose from the crankcase vent hose.
- 15.
Disconnect the electrical connector and the wire retainers. If equipped, disconnect the block heater.
- 19.
Disconnect the wire retainer and remove the nut for the ground wire. Disconnect the fuel injector electrical connectors and release the harness from the valve cover.
- 38.NOTE: Make sure that the fuel injector return line fitting retaining clips are removed prior to disconnecting the fuel injector fuel return lines from the fuel injectors or damage to the fuel injector return line fittings may occur.NOTE: The release slide is a disassembly aid only to help disconnect the fuel injector return line fitting from the fuel injector.NOTE: Be prepared to collect escaping fluid.
Remove and discard the fuel injector fuel return line fitting retaining clips from the fuel injectors.
- Push on the release the slide while pulling up on the fuel injector return line fittings to disconnect the fuel injector fuel return lines from the fuel injectors. Remove the fuel pump supply tube and return tube assemblies. Discard the return tube assembly. Refer to: Quick Release Coupling .
- 42.
Using the special tool, loosen the crankshaft pulley bolts.Use Special Service Tool: 303-1310 Holding Wrench, Crankshaft.
- 45.
Using the special tool, release the crankshaft front seal from the engine front cover.Use Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.
- 49.NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces of the engine block. These tools cause scratches and gouges, which make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.
Make sure that the mating surface is clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
Use the General Equipment: Plastic Scraper
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 50.NOTE: On early build vehicle there will not be a timing mark on the fuel injection pump sprocket.
Align the timing marks on the timing chain.
- 51.NOTE: When the tool is properly installed, the locating pin will be at approximately at the 10 o'clock position.
Using the special tool, set the crankshaft position.
Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- 53.
- 1.
Using the special tool, release the timing chain tensioner.Use Special Service Tool: 100-010 Remover, O-Ring Seal.
- 2.
Push the plunger into the timing chain tensioner.
- 3.
Using the General Equipment: 2 mm Punch, install the 2 mm punch into the timing chain tensioner.Use the General Equipment: 2 mm Punch
- 1.
- 57.NOTE: Make sure that all openings are sealed with new blanking caps.
Remove and discard the fuel injector supply tubes.
- 58.NOTE: Make sure that all openings are sealed with new blanking caps.
Remove the bolts and the fuel rail supply tube. Discard the fuel rail supply tube.
- 61.NOTE: Do not use the actuator hollow screw and electrical connector housing for removal or damage to the fuel injectors will occur.NOTE: The PCM is programmed with an IQA code for each fuel injector. Note the fuel injector cylinder location for installation.
Remove the fuel injector clamp bolts. Remove the fuel injector clamps and the fuel injectors.
- 68.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.
Clean the valve cover.
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 73.NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.
Make sure that the mating surface is clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
Use the General Equipment: Plastic Scraper
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 74.NOTE: The glow plugs protrude past the lower face of the cylinder head, any impact on the tip of the glow plug may result in glow plug damage.NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.NOTE: Use the help of an assistant to remove the cylinder head.
Remove and discard the bolts. Remove the cylinder head.
- 76.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 metal surface prep.NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
Clean the cylinder head sealing surfaces.
Use the General Equipment: Plastic Scraper
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 77.
Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- 78.
Check the cylinder block distortion. Refer to: Cylinder Block Distortion .