Cylinder Head: Material

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

ITEM SPECIFICATION

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

All cylinder heads

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.

Remove the engine. For additional information, refer to ENGINE .

NOTE: Flexplate shown in illustration, flywheel similar.

Fig 1: Locating Flexplate Bolts

Courtesy of FORD MOTOR CO.

Remove the 8 bolts and the flexplate or flywheel.
Install the engine onto a suitable engine stand.
Remove the Engine Lifting Bracket.

Fig 2: Installing Modular Engine Lift Bracket (303-F047)
Courtesy of FORD MOTOR CO.
If equipped with cylinder block drain plugs, remove the 3 bolts and the RH engine support insulator bracket.
- Discard the bolts.
  
  Fig 3: Locating RH Engine Support Insulator Bracket And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: LH shown in illustration, RH similar.

Fig 4: Locating Cylinder Block Drain Plugs

Courtesy of FORD MOTOR CO.

If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.

NOTE: LH shown in illustration, RH similar.

If equipped, install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 5: Locating Cylinder Block Drain Plugs
  Courtesy of FORD MOTOR CO.

NOTE: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged.

NOTE: The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.

Fig 6: Removing Cooling Fan And Clutch Assembly

Courtesy of FORD MOTOR CO.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan.
Disconnect the RH Camshaft Position (CMP) sensor electrical connector.

Fig 7: Locating RH Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the stud bolt and the RH radio ignition interference capacitor.

Fig 8: Locating Radio Ignition Interference Capacitor And Stud Bolt
Courtesy of FORD MOTOR CO.
Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.

Fig 9: Locating VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.

Fig 10: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the stud bolt and the LH radio ignition interference capacitor.

Fig 11: Locating Radio Ignition Interference Capacitor And Stud Bolt
Courtesy of FORD MOTOR CO.
Disconnect the engine wiring harness position retainers from the front of the RH valve cover.

Fig 12: Locating RH Valve Cover
Courtesy of FORD MOTOR CO.
Disconnect the engine wiring harness position retainers from the front of the LH valve cover and the LH CMP sensor electrical connector.

Fig 13: Locating LH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector.

Fig 14: Locating Engine Oil Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.

Fig 15: Locating Engine Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Remove the engine wiring harness from the engine assembly.

NOTE: RH shown in illustration, LH similar.

Remove the 8 bolts and the 8 ignition coils.
- Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.
  
  Fig 16: Locating Ignition Coil Bolts
  Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the oil level indicator tube.
- Discard the O-ring seal.
  
  Fig 17: Locating Oil Level Indicator Tube And Bolts
  Courtesy of FORD MOTOR CO.

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. Failure to follow this procedure can cause future oil leakage.

NOTE: When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

NOTE: The fasteners are part of the valve cover and should not be removed.

NOTE: LH shown in illustration, RH similar.

Remove the valve covers.
- Fully loosen the fasteners 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.
  
  Fig 18: Removing Valve Covers
  Courtesy of FORD MOTOR CO.
Remove the 5 bolts, coolant pump pulley and accessory drive belt idler pulley.

Fig 19: Identifying Coolant Pump Pulley And Idler Pulley Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the crankshaft pulley bolt. Using the 3 Jaw Puller, remove the crankshaft pulley.

Fig 20: Removing Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft seal.

Fig 21: Removing Crankshaft Front Seal Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.

Fig 22: Removing Front Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 15 fasteners.
Remove the 4 front oil pan bolts.

Fig 23: Locating Front Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Remove the engine front cover from the cylinder block.

Fig 24: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.
Remove the crankshaft sensor ring from the crankshaft.

Fig 25: Locating Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
Position the crankshaft keyway at the 12 o'clock position.

Fig 26: Locating Crankshaft Keyway At 12 O'Clock Position
Courtesy of FORD MOTOR CO.

NOTE: If the camshaft lobes are not exactly positioned as shown in illustration, the crankshaft will require one full additional rotation to 12 o'clock.

Fig 27: Identifying Position Of Intake Camshaft Lobes And Exhaust Lobe On No. 1 Cylinder

Courtesy of FORD MOTOR CO.

The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.

NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage.

Fig 28: Locating Camshaft Roller Followers And Bolts

Courtesy of FORD MOTOR CO.

Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.

NOTE: Do not allow the valve keepers to fall off of 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.

Fig 29: Removing Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated in the previous step from the RH cylinder head.

Fig 30: Removing Camshaft Roller Followers And Bolts

Courtesy of FORD MOTOR CO.

Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.

NOTE: Do not allow the valve keepers to fall off of 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.

Fig 31: Removing Valve Spring Compressor

Courtesy of FORD MOTOR CO.

Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated in the previous step from the LH cylinder head.

NOTE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.

Fig 32: Positioning Crankshaft Keyway

Courtesy of FORD MOTOR CO.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.

NOTE: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.

Fig 33: Locating LH Timing Chain Tensioner Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.

Fig 34: Locating RH Timing Chain Tensioner And Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
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.
  
  Fig 35: Locating Timing Chains And Crankshaft Sprocket (RH And LH)
  Courtesy of FORD MOTOR CO.

NOTE: RH shown in illustration, LH similar.

Remove the LH and RH timing chain guides.
- Remove the 4 bolts.
- Remove both timing chain guides.
  
  Fig 36: Locating Timing Chain Guide And Mounting Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket.

Using the Cam Phaser Locking Tool, remove the bolt and the RH camshaft phaser and sprocket assembly.
- Discard the camshaft phaser and sprocket bolt.
  
  Fig 37: Locating VCT Phaser Sprocket Bolt And Holder Tool
  Courtesy of FORD MOTOR CO.

NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket.

Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser and sprocket assembly.
- Discard the camshaft phaser and sprocket bolt.
  
  Fig 38: Removing LH Camshaft Phaser And Sprocket Assembly
  Courtesy of FORD MOTOR CO.

NOTE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.

Fig 39: Locating Camshaft Front Bearing Cap And Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.

NOTE: 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.

Fig 40: Identifying Camshaft Bearing Caps Bolts In Tightening Sequence

Courtesy of FORD MOTOR CO.

Remove the remaining 8 bolts in the sequence shown in illustration and remove the RH cylinder head camshaft bearing caps.
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.
  
  Fig 41: Locating Camshaft Front Thrust Bearing Cap Oil Metering Groove
  Courtesy of FORD MOTOR CO.
Remove the RH camshaft.

NOTE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.

Fig 42: Locating Camshaft Front Bearing Cap And Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.

NOTE: 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.

Fig 43: Identifying Camshaft Bearing Caps Bolts In Tightening Sequence

Courtesy of FORD MOTOR CO.

Remove the remaining 8 bolts in the sequence shown in illustration and remove the LH cylinder head camshaft bearing caps.
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.
  
  Fig 44: Locating Camshaft Front Thrust Bearing Cap Oil Metering Groove
  Courtesy of FORD MOTOR CO.
Remove the LH camshaft.

Remove the all of the remaining camshaft roller followers from the cylinder heads.
LH cylinder head

Remove the hydraulic lash adjusters from the LH cylinder head.
Remove the bolt and the intake manifold vacuum tube support bracket.

Fig 45: Locating Intake Manifold Vacuum Tube Support Bracket And Bolt
Courtesy of FORD MOTOR CO.
Install the Cylinder Head Remover/Installer onto the LH cylinder head.

Fig 46: Installing Special Tool Onto Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the 8 nuts, the 8 studs and the LH exhaust manifold.
- Discard the gaskets, the 8 studs and the 8 nuts.
- Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  
  Fig 47: Locating Exhaust Manifold Bolt
  Courtesy of FORD MOTOR CO.
RH cylinder head

Remove the hydraulic lash adjusters from the RH cylinder heads.
Remove the stud bolt and the coolant tube.
- Discard the O-ring seals.
  
  Fig 48: Locating Coolant Tube Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the Cylinder Head Remover/Installer onto the RH cylinder head.

Fig 49: Installing Cylinder Head Remover/Installer Onto RH Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the 8 nuts, the 8 studs and the RH exhaust manifold.
- Discard the gaskets, the 8 studs and the 8 nuts.
- Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  
  Fig 50: Locating RH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
All cylinder heads

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: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

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

NOTE: RH shown in illustration, LH similar.

Remove the bolts and the cylinder head.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts.
  
  Fig 51: Locating Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.

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.
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.

NOTE: LH shown in illustration, RH similar.

Fig 52: Locating Oil Pressure Feed Area

Courtesy of FORD MOTOR CO.

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 .