Cylinder Head Assembly: Service and Repair
Cylinder Heads
Removal
1. Drain engine cooling system.
2. Disconnect battery ground cable (14301).
3. Remove engine air cleaner (ACL) (9600) including air cleaner outlet tube (9B659).
4. Loosen drive belt tensioner (6B209). Remove drive belts (8620).
5. If LH cylinder head (6049) is being removed, perform the following:
Note: For SC engine, refer to Supercharger for charge air cooler (CAC) and supercharger Removal and Installation procedures. Refer to Supercharger .
a. Remove supercharger (6F066) and charge air cooler (CAC) inlet and outlet tubes.
b. Remove oil filler cap (6766).
c. Remove power steering pump front mounting bracket retaining bolts.
d. Remove generator (GEN) (10346) and belt idler pulley (8678).
e. Remove power steering pump/generator bracket retaining bolts. Leave hoses connected, place pump/bracket assembly aside in a position to prevent fluid from leaking out.
6. If RH cylinder head is being removed, perform the following:
a. Remove drive belts.
b. If equipped with A/C, remove mounting bracket retaining bolts. Leave hoses connected and position A/C compressor (19703) aside.
c. Remove positive crankcase ventilation valve (PCV valve) (6A666).
7. Remove upper intake manifold (9424). On SC engine, remove supercharger .
8. Remove valve cover retaining bolts.
9. Remove fuel injection supply manifold (9F792).
10. Remove lower intake manifold as outlined.
11. Remove exhaust manifolds (9340) as outlined.
12. Loosen rocker arm seat retaining bolts enough to allow rocker arm (6564) to be lifted off the push rod (6565) and rotate to one side.
13. Remove push rods. Identify position of each push rod. Push rods should be installed in their original position during assembly.
14. Remove cylinder head retaining bolts and discard.
15. Remove cylinder heads.
16. Remove and discard old head gaskets (6051).
17. If disassembling cylinder heads, refer to cylinder head, Disassembly.
Installation
Note: Lightly oil all bolts and stud bolt threads before installation except those specifying special sealant.
1. Clean cylinder head, intake manifold, valve cover (6582) and head gasket surfaces. If cylinder head removed for head gasket replacement, check flatness and sealing areas for scratches of cylinder head and cylinder block gasket surfaces.
2. Position new head gaskets onto cylinder block (6010) using cylinder head to block dowels (6A008) for alignment.
3. Position cylinder heads onto cylinder black.
Caution: Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface area.
Note: SC engines use torque-to-yield head bolts with large head surfaces.
Note: When cylinder head retaining bolts have been tightened as outlined, it is not necessary to retighten bolts after extended engine operation. However, bolts can be checked for tightness if desired.
4. For SC engines, tighten cylinder head retaining bolts in numerical sequence in four steps:
a. 20 Nm (15 lb ft).
b. 40 Nm (29 lb ft).
c. 60 Nm (45 lb ft).
d. 80 Nm (59 lb ft).
Caution: Do not loosen all of the bolts at the same time, only work on one bolt at a time or possible damage to engine or leakage may occur,
e. Back off retaining bolts one at a time two to three revolutions.
f. Tighten long and short bolts in numerical sequence:
a. Tighten to 15-25 Nm (11-19 lb ft).
b. Rotate an additional 175-185 degrees.
c. Go to next bolt in sequence.
5. For non-SC engine, tighten cylinder head retaining bolts in numerical sequence in three steps as follows:
a. 20 Nm (15 lb ft)
b. 40 Nm (29 lb ft)
c. 50 Nm (37 lb ft)
Caution: Do not loosen all of the bolts at the same time, only work on one bolt at a time or possible damage to engine or leakage may occur.
6. In sequence, loosen retaining bolts two to three revolutions and retighten bolts one at a time in the following manner:
a. Long bolts:
- 15-25 Nm (11-18 lb ft).
- Tighten bolt an additional 85-95 degrees.
- Go to next bolt in sequence.
b. Short bolts:
- 10-20 Nm (7-15 lb ft).
- Tighten bolt an additional 85-95 degrees.
- Go to next bolt in sequence.
Note: If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check as outlined.
7. Dip each push rod end in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford Specification ESR-M99C80-A and install push rods in their original position.
8. For each valve, rotate crankshaft (6303) until valve tappet (6500) rests on the heel (base circle) of the camshaft lobe, before tightening rocker arm seat retaining bolts to 7-15 Nm (5-11 lb ft) maximum.
9. Lubricate all rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford Specification ESR-M99C80-A.
Final-tighten the rocker arm seat bolts to 30-40 Nm (22-30 lb ft). For final tightening, camshaft (6250) may be in any position.
10. Install exhaust manifolds as outlined.
11. Install lower intake manifold as outlined.
12. Install fuel injection supply manifold.
13. Position valve cover and new valve cover gasket (6584) on cylinder head and install retaining bolts. Note location of ignition wire routing clip stud bolts. Tighten retaining bolts to 9-12 Nm (7-9 lb ft).
14. Install upper intake manifold . Install supercharger .
15. Install spark plugs (12405), if removed.
16. Connect ignition wires to the spark plugs.
17. If LH cylinder head is being installed, perform the following:
a. Install oil filler cap.
b. Install generator/power steering pump mounting bracket.
c. Install generator.
d. Install main accessory drive belt tensioner
e. Install power steering pump (3A674).
f. Install power steering pump support bracket. Install charge air cooler (CAC) tubes (SC engine only).
18. If RH cylinder head is being installed, perform the following:
a. Install positive crankcase ventilation valve.
b. If equipped with A/C, install A/C compressor mounting brackets (2882) and A/C compressor.
19. Install drive belt and tighten to specification.
20. Connect battery ground cable.
21. Install air cleaner outlet tube.
Caution: This engine has aluminum cylinder heads and requires a special corrosion inhibited coolant formulation to avoid cooling system damage.
22. Fill engine cooling system with specified coolant.
23. Start engine and check for coolant, fuel and oil leaks.