Attachment III - Technical Information

HEAD GASKET REPLACEMENT

AFFECTED VEHICLES:
1994 CONTINENTAL, 1994-95 TAURUS/SABLE AND 1995 WINDSTAR EQUIPPED WITH 3.8L FWD ENGINE

INSPECTION
Verify coolant loss, due to leakage past the head gasket, by performing the cylinder compression test procedure as outlined in Section 03-00 of the appropriate Service Manual.

^ If engine passes the compression test, no service action is required. Return vehicle to the customer.

^ If engine fails the compression test, replace head gaskets as outlined under "Service Procedure".

SERVICE PROCEDURE

1. Remove cylinder head and clean gasket surface following the procedure outlined in Section 03-01 of the appropriate Service Manual.

2. Check cylinder head flatness following the procedure outlined in Section 03-00 of the appropriate Service Manual.

3. Replace the cylinder head gaskets and cylinder head bolts.





4. Reassemble and torque the new head bolts to the following specifications: Torque all bolts in numerical sequence, Figure 1, in three steps as follows:

^ 20 Nm (15 lb/ft).

^ O 40 Nm(30 lb/ft).

^ O 50 Nm(37 lb/ft).

CAUTION
Do not loosen all of the bolts at the same time. Work on one bolt at a time in the sequence shown in Figure 1. Failure to loosen bolts in proper sequence could cause cylinder head to warp.

5. In numerical sequence, as shown in Figure 1, retorque the bolts per the following steps:

LONG BOLTS:

a) Loosen long bolt and back out 2-3 turns.

b) Retorque long bolt to 40-50 Nm (30-37 lb/ft).

c) Rotate long bolt an additional 175-185 degrees (approximately 1/2 turn).

d) Go to the next bolt in sequence.

SHORT BOLTS:

a) Loosen short bolt and back out 2-3 turns.

b) Retorque short bolt to 20-30 Nm (15-22 lb/ft).

c) Rotate short bolt an additional 175-185 degrees (approximately 1/2 turn).

d) Go to next bolt in sequence.