Part 1

Cylinder Head

Special Tool(s):

Special Tool(s):

Material:

Both cylinder heads

1. CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.

NOTE: RH head gasket shown, LH head gasket similar.

Install the head gasket over the dowel pins.





2. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.

CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. 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.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.

NOTE: LH shown, RH similar.

Install the cylinder head on the dowels and the head gasket.
- Loosely install the new bolts.





RH cylinder head
3. Tighten the new cylinder head bolts in 5 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten to 50 Nm (37 ft. lbs.).
- Stage 3: Tighten to 80 Nm (59 ft. lbs.).
- Stage 4: Tighten an additional 90 degrees.
- Stage 5: Tighten an additional 90 degrees.

RH:

4. Install the 3 coolant tube assembly bolts.
- Tighten 10 Nm (89 inch lbs.).





5. Install new RH exhaust manifold gaskets, the RH exhaust manifold and 8 new nuts.
- Tighten in the sequence shown to 20 Nm (15 ft. lbs.).





LH cylinder head
6. Tighten the new cylinder head bolts in 5 stages in the sequence shown.
- Stage 1: Tighten to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten to 50 Nm (37 ft. lbs.).
- Stage 3: Tighten to 80 Nm (59 ft. lbs.).
- Stage 4: Tighten an additional 90 degrees.
- Stage 5: Tighten an additional 90 degrees.

LH:

7. Install new LH exhaust manifold gaskets, the LH exhaust manifold and 8 new nuts.
- Tighten in the sequence shown to 20 Nm (15 ft. lbs.).





Both cylinder heads

8. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using an edge of a vise.





9. Using a small screwdriver or pick, push back and hold the ratchet mechanism.





10. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





11. Install a suitable pin into the hole of each tensioner housing to hold the ratchet assembly and plunger in place during installation.
- Remove the tensioner from the vise.





12. If the colored links are not visible, mark one link on one end and 2 links on the other end, and use as timing marks.





13. Using the special tool, position the crankshaft.





14. Install the crankshaft sprocket with the flange facing forward.





15. Install the LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 inch lbs.).





16. Position the camshaft sprocket timing marks as shown.





17. Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one colored link on the timing chain with the slot on the crankshaft sprocket.





18. Install the LH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.





19. Install the LH primary timing chain tensioner arm.





20. Install the LH primary timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 ft. lbs.).
- Remove the pin from the tensioner.





21. Install the RH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 inch lbs.).





22. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored link with the timing marks on the sprocket.





23. Install the RH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.





24. Install the RH primary timing chain tensioner arm.





25. Install the RH primary timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 ft. lbs.).
- Remove the pin from the tensioner.





26. As a post-check, verify correct alignment of all timing marks. Make sure that the colored links are lined up with the marks on the crankshaft sprocket and the camshaft sprockets.





27. Install the crankshaft sensor ring.





28. CAUTION: If the components are to be reinstalled, they must be installed in their original positions.

Install the hydraulic lash adjusters.





29. Using the special tool, compress the valve spring and install the roller follower.





30. Repeat the previous step to install all the roller followers.

31. NOTE: RH shown, LH similar.

Install the 8 spark plugs.
- Tighten to 18 Nm (13 ft. lbs.).

32. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.

Apply silicone gasket and sealant in the locations shown.





33. Install the engine front cover and the 16 bolts. Tighten the bolts in the sequence shown:
- Bolts 1 through 14 to 25 Nm (18 ft. lbs.).
- Bolts 15 and 16 to 50 Nm (37 ft. lbs.).





34. Install the 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts.
- Tighten to 25 Nm (18 ft. lbs.).





35. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.





36. Using the special tool, install the crankshaft front seal.





37. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





38. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.





39. Using the special tool, install the crankshaft pulley.





40. Using the special tool, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
- Stage 1: Tighten to 90 Nm (66 ft. lbs.).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 ft. lbs.).
- Stage 4: Tighten an additional 90 degrees.