Cylinder Head: Material

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

MATERIAL SPECIFICATIONS

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

All cylinder heads

Remove the engine. For additional information, refer to ENGINE .
Remove the bolts and the flexplate or flywheel.

Fig 1: Locating 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.

Lower and support the engine assembly on wood blocks.
Remove the Engine Lifting Bracket.

Fig 2: Identifying Engine Lifting Bracket (303-F047)
Courtesy of FORD MOTOR CO.
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.

If equipped with cylinder block drain plugs, remove the 3 bolts and the RH engine support insulator bracket.
- Discard the 3 engine support insulator bracket bolts.
  
  Fig 3: Locating Engine Support Insulator Bracket Bolts
  Courtesy of FORD MOTOR CO.

NOTE: LH shown in illustration, RH similar.

Fig 4: Locating Cylinder Block Drain Plug

Courtesy of FORD MOTOR CO.

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

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

Fig 5: Removing/Installing Engine Cooling Fan

Courtesy of FORD MOTOR CO.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the engine cooling fan from the coolant pump pulley.
Disconnect the Camshaft Position (CMP) sensor electrical connector.

Fig 6: Locating CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the nut and the RH radio ignition interference capacitor.

Fig 7: Locating Radio Ignition Interference Capacitor And Nut
Courtesy of FORD MOTOR CO.
Disconnect the 10 ignition coil electrical connectors.

Fig 8: Locating Ignition Coil Electrical Connector
Courtesy of FORD MOTOR CO.
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 Coil Bolt
  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.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector.

Fig 11: Locating Engine Oil Pressure (EOP) Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the nut and the LH radio ignition interference capacitor.

Fig 12: Locating Radio Ignition Interference Capacitor And Nut
Courtesy of FORD MOTOR CO.
Disconnect the Crankshaft Position (CKP) sensor electrical connector.

Fig 13: Locating Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the engine harness retainers and remove the engine wiring harness from the engine assembly.
Remove the 2 bolts and the oil level indicator tube.
- Discard the O-ring seal.
  
  Fig 14: Locating Oil Level Indicator Tube 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.

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

Loosen the 16 fasteners in the sequence shown in illustration and remove the RH valve cover and gasket.
- 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 15: Identifying RH Valve Cover Fasteners Loosening Sequence
  Courtesy of FORD MOTOR CO.

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

Loosen the 17 fasteners in the sequence shown in illustration and remove the LH valve cover and gasket.
- 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 16: LH Valve Cover Fasteners Tightening/loosening Sequence
  Courtesy of FORD MOTOR CO.
Remove the 5 bolts, coolant pump pulley and accessory drive belt idler pulley.

Fig 17: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the accessory drive belt tensioner.

Fig 18: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
Remove the crankshaft pulley bolt and washer.
- Discard the crankshaft pulley bolt.
Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.

Fig 19: Removing Crankshaft Pulley Using Crankshaft Vibration Damper Remover
Courtesy of FORD MOTOR CO.
Using the Crankshaft Front Seal Remover, remove and discard the crankshaft front seal.

Fig 20: Locating Crankshaft Front Seal And Crankshaft Front Oil Seal Remover
Courtesy of FORD MOTOR CO.
Remove the front 4 oil pan bolts.

Fig 21: Locating Front Oil Pan Bolts
Courtesy of FORD MOTOR CO.

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

Fig 22: Locating Front Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 15 fasteners.
Remove the engine front cover from the cylinder block.

Fig 23: 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.

Fig 24: Locating Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Loosen and back off the RH camshaft sprocket bolt one full turn.

NOTE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.

Fig 25: Locating Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Loosen the LH camshaft sprocket bolt.

NOTE: The balance shaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.

Fig 26: Identifying Balance Shaft Bearing Cap Bolt Loosening/Tightening Sequence

Courtesy of FORD MOTOR CO.

Using the sequence shown in illustration, remove the 6 bolts, then the 3 balance shaft bearing caps and the balance shaft.
Remove the crankshaft sensor ring from the crankshaft.

Fig 27: Locating Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
Position the crankshaft keyway at the 12 o'clock position.

Fig 28: Positioning 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 29: 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 their original locations or engine damage may occur. Mark the components for installation into their original locations.

Fig 30: Locating Camshaft Roller Followers

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 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/Installing Camshaft Roller Followers Using Valve Spring Compressor

Courtesy of FORD MOTOR CO.

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

Fig 32: Locating Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Remove only the 4 camshaft roller followers shown in the illustration from the LH cylinder head.

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.

Fig 33: Removing/Installing Camshaft Roller Followers Using Valve Spring Compressor

Courtesy of FORD MOTOR CO.

Using the Valve Spring Compressor, remove the 4 designated camshaft roller followers 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 34: Positioning Crankshaft Keyway At 6 O'Clock Position

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 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.

Fig 35: Locating LH Timing Chain Tensioner And Tensioner Arm With Mounting Bolts

Courtesy of FORD MOTOR CO.

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

Fig 36: Locating RH Timing Chain Tensioner And Tensioner Arm With Mounting Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
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 37: Removing LH And RH Timing Chain And Crankshaft Sprockets
  Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the timing chain guides.

Fig 38: Locating Timing Chain Guides With Mounting Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts and the RH and LH camshaft sprockets.
Remove the balance shaft drive gear from the LH camshaft.

Fig 39: Locating Balance Shaft Drive Gear
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 40: Locating RH Camshaft Front Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the RH 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 41: RH Cylinder Head Camshaft Bearing Cap Bolts Removing Sequence

Courtesy of FORD MOTOR CO.

Remove the 10 remaining 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 42: 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 43: Locating LH Camshaft Front Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the LH 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 44: LH Cylinder Head Camshaft Bearing Cap Bolts Loosening Sequence

Courtesy of FORD MOTOR CO.

Remove the 10 remaining 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 45: Locating Camshaft Front Thrust Bearing Cap Oil Metering Groove
  Courtesy of FORD MOTOR CO.
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.

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.

Remove the hydraulic lash adjusters from the LH cylinder head.
Install the Cylinder Head Remover/Installer onto the LH cylinder head.

Fig 46: Identifying Cylinder Head Remover/Installer On LH Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the exhaust manifold heat shield.

Fig 47: Locating Exhaust Manifold Heat Shield Bolts
Courtesy of FORD MOTOR CO.
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 .
  
  Fig 48: Removing LH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Remove and discard the 10 exhaust manifold-to-cylinder head studs.

Fig 49: 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.

Remove the hydraulic lash adjusters from the RH cylinder head.
Install the Cylinder Head Remover/Installer onto the RH cylinder head.

Fig 50: Identifying Cylinder Head Remover/Installer On RH Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the heater coolant tube stud bolt.

Fig 51: Locating Coolant Tube Stud Bolt
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the exhaust manifold heat shield.

Fig 52: Locating Exhaust Manifold Heat Shield Bolts
Courtesy of FORD MOTOR CO.
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 .
  
  Fig 53: Removing RH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Remove and discard the 10 exhaust manifold-to-cylinder head studs.

Fig 54: 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 in illustration, LH similar.

Remove the 12 bolts and the cylinder head.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts.
  
  Fig 55: Removing Cylinder Head
  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 or engine damage may occur.

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.

NOTE: LH shown in illustration, RH similar.

Fig 56: 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 .