Removal and Replacement

Cylinder Head

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Material(s)






Removal

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

2. Drain the cooling system. REFER to Cooling System Draining .

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

4. Remove the HO2S (Heated Oxygen Sensor) sensor. REFER to Heated Oxygen Sensor (HO2S) .

5. Disconnect the CMS (Catalyst Monitor Sensor) electrical connector.

- Detach the CMS (Catalyst Monitor Sensor) wire from the wiring harness retainer.






6. Remove and discard the engine oil filter.





7. Remove the 4 bolts and the catalytic converter heat shield.

- Position the CMS (Catalyst Monitor Sensor) wiring harness bracket aside.






8. Remove the 2 bolts from the catalytic converter lower bracket.





9. Remove the 2 catalytic converter-to-muffler nuts.

- Discard the gasket.






10. Remove the 2 bolts for the catalytic converter hanger.





11. Remove the 5 catalytic converter manifold-to-cylinder head nuts and position the catalytic converter back.

- Discard the nuts and catalytic converter gasket.






12. Remove the 5 catalytic converter-to-cylinder head studs and discard.





13. Remove the camshafts. REFER to Camshafts .

14. Remove the ground strap bolt from the LH (Left Hand) side of cylinder head.





15. Detach the wiring harness retainer from the RH (Right Hand) rear side of the cylinder head.





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

- Disconnect the ECT (Engine Coolant Temperature) sensor electrical connector.
- Detach the 2 coolant hose retaining clips.






17. NOTE: If the 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.





18. Remove the 10 bolts and the cylinder head.

- Discard the bolts.






19. Remove and discard the head gasket.





Installation

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. 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. Clean and inspect the catalytic converter flange. REFER to Exhaust Manifold Cleaning and Inspection .

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

4. Install a new cylinder head gasket.





5. 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 45 Nm (33 lb-ft).
- Stage 4: Tighten 90 degrees.
- Stage 5: Tighten an additional 90 degrees.





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





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

- Connect the ECT (Engine Coolant Temperature) sensor electrical connector.
- Attach the 2 coolant hose retaining clips.






8. Attach the wiring harness retainer to the RH (Right Hand) rear side of the cylinder head.





9. Install the ground wire and bolt on the LH (Left Hand) side of the cylinder head.
- Tighten to 10 Nm (89 lb-in).





10. Install the camshafts. REFER to Camshafts .

11. Install the 5 new catalytic converter-to-cylinder head studs.
- Tighten to 17 Nm (150 lb-in).





12. NOTICE: Failure to tighten the catalytic converter manifold nuts to specification a second time may cause the converter to develop an exhaust leak.

NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket installation to make sure of proper sealing.
Using a new gasket, position the catalytic converter and install the 5 catalytic converter manifold-to-cylinder head nuts and tighten in 2 stages in the sequence shown.
- Stage 1: Tighten to 55 Nm (41 lb-ft).
- Stage 2: Tighten to 55 Nm (41 lb-ft).





13. Install the 2 bolts for the catalytic converter hanger.
- Tighten to 25 Nm (18 lb-ft).





14. Install the 2 nuts to the catalytic converter-to-muffler.
- Tighten the first nut to 48 Nm (35 lb-ft).
- Tighten the second nut to 48 Nm (35 lb-ft).
- Re-tighten the first nut to 48 Nm (35 lb-ft).





15. Install the 2 bolts for the catalytic converter lower bracket.
- Tighten to 25 Nm (18 lb-ft).





16. Install the catalytic converter heat shield, CMS (Catalyst Monitor Sensor) wiring harness bracket and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





17. Connect the CMS (Catalyst Monitor Sensor) electrical connector.

- Attach the CMS (Catalyst Monitor Sensor) wire to the wiring harness retainer.






18. Install the HO2S (Heated Oxygen Sensor) sensor. REFER to Heated Oxygen Sensor (HO2S) .

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





20. 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.





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

22. Fill the cooling system. REFER to Cooling System Filling And Bleeding - With A Vacuum Cooling System Filler or REFER to Cooling System Filling And Bleeding - Without A Vacuum Cooling System Filler .

23. Fill the engine with clean engine oil.