Cylinder Head

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Compressor, Valve Spring	303-1039
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket	303-F047 (014-00073) or equivalent
Courtesy of FORD MOTOR CO.	Fan Clutch Nut Wrench	303-214 (T83T-6312-B)
Courtesy of FORD MOTOR CO.	Fan Pulley Holding Wrench	303-478 (T94T-6312-AH)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Front Seal	303-107 (T74P-6700-A)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Vibration Damper	303-009 (T58P-6316-D)
Courtesy of FORD MOTOR CO.	Remover/Installer, Cylinder Head	303-572 (T97T-6000-A)

All cylinder heads 

1. Remove the engine. For additional information, refer to Engine .
2. Remove the bolts and the flexplate or flywheel.
Fig 1: Identifying Flexplate Bolts
Courtesy of FORD MOTOR CO.
NOTE: Do not use the oil pan to support the engine or oil pan and oil pan gasket damage may occur.
3. Lower and support the engine assembly on wood blocks.
4. Remove the Engine Lifting Bracket.
Fig 2: Identifying Special Tool (303-F047)
Courtesy of FORD MOTOR CO.
5. Install the engine assembly onto a suitable engine stand.
NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
6. Remove the 3 bolts and the RH engine support insulator bracket.
   • Discard the 3 engine support insulator bracket bolts.
Fig 3: Locating Bolts On RH Engine Support Insulator Bracket
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
7. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
Fig 4: Locating Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
NOTE: The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.
8. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the engine cooling fan from the coolant pump pulley.
Fig 5: Fan Clutch Assembly Nut - 6.8L
Courtesy of FORD MOTOR CO.
9. Disconnect the Camshaft Position (CMP) sensor electrical connector.
Fig 6: Identifying RH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
10. Remove the nut and the RH radio ignition interference capacitor.
Fig 7: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
Courtesy of FORD MOTOR CO.
11. Disconnect the 10 ignition coil electrical connectors.
Fig 8: Locating Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
12. Remove the 10 bolts and the 10 ignition coils.
    • Remove the ignition coil by using a twisting motion while pulling up on the ignition coil.
Fig 9: Locating Ignition Coils Bolts
Courtesy of FORD MOTOR CO.
13. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
Fig 10: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
14. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
Fig 11: Identifying Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
15. Remove the nut and the LH radio ignition interference capacitor.
Fig 12: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
Courtesy of FORD MOTOR CO.
16. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
Fig 13: Locating CKP Sensor Electrical Connector And Harness Retainer
Courtesy of FORD MOTOR CO.
17. Disconnect the engine harness retainers and remove the engine wiring harness from the engine assembly.
18. Remove the 2 bolts and the oil level indicator tube.
    • Discard the O-ring seal.
Fig 14: Locating Bolts On Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
19. Remove the bolt and the CMP sensor.
Fig 15: Locating Camshaft (CMP) Sensor Bolt
Courtesy of FORD MOTOR CO.
20. Remove the bolt and the CKP sensor.
Fig 16: Locating Crankshaft Position (CKP) Sensor Bolt
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.
NOTE: The bolts are part of the valve cover and should not be removed.
21. Loosen the 16 fasteners in the sequence shown and remove the RH valve cover and gasket.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and motorcraft 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: Identifying Valve Cover Fasteners Loosening/Tightening Sequence
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.
NOTE: The bolts are part of the valve cover and should not be removed.
22. Loosen the 17 fasteners in the sequence shown and remove the LH valve cover and gasket.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and motorcraft 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: Identifying Valve Cover Fasteners Tightening Sequence
Courtesy of FORD MOTOR CO.
23. Remove the 5 bolts, coolant pump pulley and accessory drive belt idler pulley.
Fig 19: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
24. Remove the 3 bolts and the accessory drive belt tensioner.
Fig 20: Identifying Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
25. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
26. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
Fig 21: Removing Crankshaft Pulley Using Special Tool (303-009)
Courtesy of FORD MOTOR CO.
27. Using the Crankshaft Front Seal Remover, remove and discard the crankshaft front seal.
Fig 22: Removing Crankshaft Front Seal Using Special Tool (303-107)
Courtesy of FORD MOTOR CO.
28. Remove the front 4 oil pan bolts.
Fig 23: Front Oil Pan Bolts
Courtesy of FORD MOTOR CO.
NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
29. Remove the 15 fasteners.
Fig 24: Locating Bolts And Studs
Courtesy of FORD MOTOR CO.
30. Remove the engine front cover from the cylinder block.
Fig 25: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
31. Loosen and back off the RH camshaft sprocket bolt one full turn.
Fig 26: Identifying Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
32. Loosen the LH camshaft sprocket bolt.
Fig 27: Identifying LH Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
NOTE: The balance shaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
33. Remove the 6 bolts in the sequence shown, the 3 bearing caps and the balance shaft.
Fig 28: Identifying Balance Shaft Bolt Loosening/Tightening Sequence
Courtesy of FORD MOTOR CO.
34. Remove the crankshaft sensor ring from the crankshaft.
Fig 29: View Of Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
35. Position the crankshaft keyway at the 12 o'clock position.
Fig 30: Positioning Crankshaft Keyway At 12 O'Clock Position
Courtesy of FORD MOTOR CO.
NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
36. 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.
Fig 31: Identifying Camshaft Lobe Position
Courtesy of FORD MOTOR CO.
NOTE: If the components are to be reinstalled, they must be installed in their original locations, or engine damage may occur. Mark the components for installation into their original locations.
37. Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
Fig 32: Identifying Camshaft Roller Followers On RH Cylinder Head
Courtesy of FORD MOTOR CO.
NOTE: Do not allow the valve keepers to fall off 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.
38. Using the Valve Spring Compressor, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head.
Fig 33: Identifying Special Tool (303-1039) For Removing/Installing Camshaft Roller Followers
Courtesy of FORD MOTOR CO.
NOTE: If the components are to be reinstalled, they must be installed in their original locations, or engine damage may occur. Mark the components for installation into their original locations.
39. Remove only the 4 camshaft roller followers shown in the illustration from the LH cylinder head.
Fig 34: Locating Camshaft Roller Followers
Courtesy of FORD MOTOR CO.
NOTE: Do not allow the valve keepers to fall off 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.
40. Using the Valve Spring Compressor, remove the 4 designated camshaft roller followers in the previous step from the LH cylinder head.
Fig 35: Compressing Spring Using Special Tool (303-1039)
Courtesy of FORD MOTOR CO.
NOTE: The crankshaft cannot be moved past the 6 o'clock position once set, or engine damage may occur.
41. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
Fig 36: Crankshaft Positioned With Keyway At 6 O'clock Position
Courtesy of FORD MOTOR CO.
NOTE: If one or both of the 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.
42. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
Fig 37: Identifying LH Timing Chain Tensioner & Tensioner Arm
Courtesy of FORD MOTOR CO.
NOTE: If one or both of the 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.
43. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
Fig 38: Locating RH Timing Chain Tensioner And Tensioner Arm
Courtesy of FORD MOTOR CO.
44. Remove the LH and RH timing chain and the crankshaft sprockets.
    • 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 the crankshaft sprocket.
Fig 39: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
Courtesy of FORD MOTOR CO.
45. Remove the 4 bolts and the timing chain guides.
Fig 40: Locating Timing Chain Guides Bolts
Courtesy of FORD MOTOR CO.
46. Remove the bolts and the RH and LH camshaft sprockets.
47. Remove the balance shaft drive gear from the LH camshaft.
Fig 41: Removing Balance Shaft Drive Gear From LH Camshaft
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.
48. Remove the 2 bolts and the RH camshaft front bearing cap.
Fig 42: Identifying Camshaft Front Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
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.
49. Remove the 10 remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.
Fig 43: Removing 10 Remaining Bolts In Sequence
Courtesy of FORD MOTOR CO.
50. 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 44: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
Courtesy of FORD MOTOR CO.
51. 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.
52. Remove the 2 bolts and the LH camshaft front bearing cap.
Fig 45: Locating Bolts On LH Camshaft Front Bearing Cap
Courtesy of FORD MOTOR CO.
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.
53. Remove the 10 remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.
Fig 46: Removing Remaining 10 Bolts In Sequence
Courtesy of FORD MOTOR CO.
54. 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 47: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
Courtesy of FORD MOTOR CO.
55. Remove the LH camshaft.
NOTE: If the components are to be reinstalled, they must be installed in their original locations, or engine damage may occur. Mark the components for installation into their original locations.
56. Remove all of the remaining roller followers from the cylinder heads.

LH cylinder head 

NOTE: If the components are to be reinstalled, they must be installed in their original locations, or engine damage may occur. Mark the components for installation into their original locations.
57. Remove the hydraulic lash adjusters from the LH cylinder head.
58. Install the Cylinder Head Remover/Installer onto the LH cylinder head.
Fig 48: Identifying Special Tool (303-572) Onto Cylinder Head
Courtesy of FORD MOTOR CO.
59. Remove the 3 bolts and the exhaust manifold heat shield.
Fig 49: Locating Bolts On Exhaust Manifold Heat Shield
Courtesy of FORD MOTOR CO.
60. Remove the 10 nuts and the LH exhaust manifold.
    • Discard the 2 gaskets and the 10 nuts.
    • Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
Fig 50: Removing LH Exhaust Manifold
Courtesy of FORD MOTOR CO.
61. Remove and discard the 10 exhaust manifold-to-cylinder head studs.
Fig 51: Locating Exhaust Manifold-To-Cylinder Head Studs
Courtesy of FORD MOTOR CO.

RH cylinder head 

NOTE: If the components are to be reinstalled, they must be installed in the same positions, or engine damage may occur. Mark the components for installation into their original locations.
62. Remove the hydraulic lash adjusters from the RH cylinder head.
63. Install the Cylinder Head Remover/Installer onto the RH cylinder head.
Fig 52: Identifying Special Tool (303-572) On Cylinder Head
Courtesy of FORD MOTOR CO.
64. Remove the heater coolant tube stud bolt.
Fig 53: Identifying Coolant Tube Stud Bolt
Courtesy of FORD MOTOR CO.
65. Remove the 2 bolts and the exhaust manifold heat shield.
Fig 54: Locating Bolts On Exhaust Manifold Heat Shield
Courtesy of FORD MOTOR CO.
66. Remove the 10 nuts and the RH exhaust manifold.
    • Discard the 2 gaskets and the 10 nuts.
    • Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
Fig 55: Removing RH Exhaust Manifold
Courtesy of FORD MOTOR CO.
67. Remove and discard the 10 exhaust manifold-to-cylinder head studs.
Fig 56: Locating Exhaust Manifold-To-Cylinder Head Studs
Courtesy of FORD MOTOR CO.

All cylinder heads 

NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can 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 or engine damage may occur.
NOTE: The cylinder head bolts must be discarded and new bolts must be installed or engine damage may occur. They are a tighten-to-yield design and cannot be reused.
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 cylinder head damage may occur.
NOTE: RH shown, LH similar.
68. Remove the 12 bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
Fig 57: Removing Bolts & Cylinder Head
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 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 motorcraft metal surface prep or engine damage may occur.
NOTE: If there is no residual gasket material present, motorcraft metal surface prep can be used to clean and prepare the surfaces.
69. 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 motorcraft 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, RH similar.
70. 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 article.
Fig 58: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
Courtesy of FORD MOTOR CO.