Removal and Replacement

Cylinder Head

Material(s)






Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: 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 can cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Jacking and Lifting .

2. Release the fuel system pressure. REFER to Fuel System Pressure Release .

3. Remove the turbocharger. REFER to Turbocharger .

4. Remove and discard the engine oil filter.





5. Remove the fuel injectors. REFER to Fuel Injectors .

6. Remove the camshafts. REFER to Camshafts .

7. Remove the bolt and ground wire from the cylinder head.





8. Disconnect the 4 coolant hoses from the coolant outlet.

- Disconnect the ECT (Engine Coolant Temperature) sensor electrical connector.






9. Slide the insulator up and disconnect the CHT (Cylinder Head Temperature) electrical connector.





10. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
Remove the 16 valve tappets.





11. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm (0.144 in).
Inspect the valve tappets. REFER to Valve Tappet Inspection .

12. Remove the 10 bolts and the cylinder head.

- Discard the bolts.






13. Remove and discard the head gasket.





Installation

NOTICE: 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.

1. 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: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.

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 surface 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 Motorcraft(R) Silicone Gasket Remover following package directions, and allow to set for several minutes.

3. Remove the Motorcraft(R) Silicone Gasket Remover with a plastic scraper. A second application of Motorcraft(R) Silicone Gasket Remover may be required if residual traces of silicone or gasket material remain.

4. Apply Motorcraft(R) Metal Surface Prep following package directions, to remove any 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.

2. Check the cylinder head distortion and the cylinder block distortion. REFER to Cylinder Head Distortion and REFER to Cylinder Block Distortion .

3. Install a new cylinder head gasket.





4. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
Install the cylinder head and the 10 new bolts.
- Tighten the bolts in the sequence shown in 5 stages.
- Stage 1: Tighten to 7 Nm (62 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 55 Nm (41 lb-ft).
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten an additional 90 degrees.





5. NOTE: Lubricate the valve tappets with clean engine oil prior to installing.
Install the 16 valve tappets in their original positions.





6. Connect the CHT (Cylinder Head Temperature) electrical connector and slide the insulator down.





7. Connect the 4 coolant hoses to the coolant outlet.

- Connect the ECT (Engine Coolant Temperature) sensor electrical connector.






8. Install the ground wire and bolt on the cylinder head.
- Tighten to 20 Nm (177 lb-in).





9. Install the camshafts. REFER to Camshafts .

10. Install the fuel injectors. REFER to Fuel Injectors .

11. Remove the drain plug and drain the engine oil.
- Install the drain plug and tighten to 27 Nm (20 lb-ft).





12. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
Install a new engine oil filter.
- Tighten to 8 Nm (71 lb-in) plus an additional 180 degrees.





13. Install the turbocharger. REFER to Turbocharger .

14. Fill the engine with clean engine oil.