Cylinder Head: Disassembly

WARNING: This page is about a different variant/trim than selected.

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: During engine repair procedures, cleanliness is extremely important. Any foreign material, including material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: If the engine components are to be reinstalled, they must be reinstalled in the same positions. Mark the components removed for locations.

Disconnect and remove the coolant hose.

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Remove the bolts. Disconnect and remove the coolant tube.

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Remove the bolts and the heat shield.

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Remove and discard the EGR cooler clamp.

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Remove the bolt for the EGR cooler. Discard the EGR valve gasket.

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Remove the bolt and the EGR cooler.

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Remove and discard the EGR cooler gasket.

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Remove the nuts and the EGR valve.

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Remove the bolts and the mixer tube.

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NOTE: The O-ring seal is to be reused unless damaged.

Inspect the O-ring. Remove and discard the gasket.

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Remove the bolts and the intake manifold.

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Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If the conditions are not present, the gaskets may be reused.

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Remove the glow plug harness.

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Remove the glow plugs.

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Remove and nuts and the exhaust manifold. Discard the nuts.

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NOTE: Only use hand tools when loosening or tightening the exhaust manifold studs or damage to the stud torx head or cylinder head threads can occur.

Remove and discard the exhaust manifold gasket. Remove and discard the exhaust manifold studs.

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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.

NOTE: Use compressed air to remove any foreign material in the stud bolt holes.

Clean the exhaust manifold mounting surface. Use the General Equipment: Plastic Scraper

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Clean and inspect the exhaust manifold Refer to: Exhaust Manifold Cleaning and Inspection .
Remove the bolt and the lifting bracket.

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NOTE: Use a commercially available valve spring compressor.

NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets.

Remove the valve collets, valve spring retainer and the valve spring.

Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

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Inspect and install new parts, as necessary.

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NOTE: Use commercially available valve stem seal pliers.

Remove and discard the valve seal.

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NOTE: Note the location of the valves if they are to be reused.

Remove the valve from the cylinder head.

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Repeat the above steps for each valve.
Inspect the intake and exhaust valve guides and valve seats.

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1. Inspect the following valve areas: The end of the stem for grooves or scoring.
2. The valve face and the edge for pits, grooves or scores.
3. The valve head for signs of burning, erosion, warpage and cracking.
4. The valve margin for wear.
- Install new parts as necessary.

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