Removal and Installation

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

REMOVAL
1. Drain engine coolant from radiator (8005) and cylinder block drain plugs.
2. Remove intake manifold (9424).
3. Remove the exhaust manifold (9430). See Exhaust System.
4. Remove camshafts (6250) and valve tappets (6500).
5. Support the front of the engine with a wood block between the crankshaft pulley and front sub-frame (5C145).
6. Remove Three Bar Engine Support D88L-6000-A or equivalent.
7. Remove the RH engine lifting eye retaining bolt and RH engine lifting eye (17A084).
8. Remove the support bracket from the power steering pump mounting bracket and cylinder head (6049).
9. Remove the camshaft timing belt tensioner pulley and the engine front cover (6019) from the front of the cylinder head.
10. Remove the water thermostat housing from the cylinder head. See Cooling System.
11. Remove the ignition coil (12029) mounting bracket from the cylinder head.
12. Remove the spark plugs (12405) from the cylinder head.

Fig. 11 Cylinder head bolt removal sequence:

13. Remove cylinder head retaining bolts in removal sequence shown.





14. Remove the cylinder head and head gasket (6051) from the cylinder block (6010).
15. If required, remove the LH engine lifting eye from the cylinder head.
16. Inspect cylinder head and cylinder block. Replace components as required.

INSTALLATION
1. Clean the cylinder head, intake manifold, valve cover (6582) and cylinder head gasket surfaces. If the cylinder head was removed for a cylinder head gasket replacement, check the flatness of the cylinder head and cylinder block gasket surfaces.
2. Install the new head gasket on the cylinder block. The head gasket must be installed over the cylinder head to block dowels.

CAUTION: Use care when positioning cylinder head. Damage to cylinder block and/or cylinder head may result.

3. Install cylinder head onto cylinder block over cylinder head to block dowels (6A008).

CAUTION: Cylinder head retaining bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused or damage to engine may occur.

Fig. 12 Cylinder head bolt tightening sequence:

4. Install new torque-to-yield cylinder head retaining bolts and tighten in sequence shown as follows:
Step 1 ... Tighten all bolts to 20-30 Nm (15-22 ft. lbs.).
Step 2 ... Tighten all bolts to 40-50 Nm (30-37 ft. lbs.).
Step 3 ... Rotate all bolts 90-120°.
5. Install the ignition coil mounting bracket and ignition coil.
6. Install the water thermostat housing. See Cooling System.
7. Install the engine front cover. Tighten retaining bolts to 8-11 Nm (71-97 inch lbs.).
8. Install the camshaft timing belt tensioner pulley onto the front of the cylinder head. Loosely install retaining bolt.
9. Install the support bracket to the power steering pump mounting bracket and the cylinder head. Tighten the retaining bolts to 39-55 Nm (29-41 ft. lbs.).





10. Install the RH engine lifting eye to the cylinder head and generator mounting bracket (10153). Tighten the retaining bolts to 41-55 Nm (30-41 ft. lbs.).
11. If removed, install the LH engine lifting eye onto the cylinder head. Tighten retaining bolt to 14-18 Nm (10-13 ft. lbs.).
12. Install Three Bar Engine Support D88L-6000-A or equivalent to the engine lifting eyes.
13. Remove the wood block from between the front sub-frame and crankshaft pulley (6312).
14. Install the valve tappets and camshafts.
15. Install the exhaust manifold.
16. Install the intake manifold.
17. Install spark plugs. See Powertrain Management.
18. Drain the engine oil from the crankcase.
19. Replace the oil bypass filter (6714).
20. Install oil pan drain plug and tighten to 21-28 Nm (15-21 ft. lbs.).
21. Fill crankcase with the proper grade and quantity of engine oil.
22. Fill engine cooling system.
23. Run engine and check for oil and coolant leaks.