Disassembly and Assembly
DISASSEMBLY1. Remove cylinder heads.
2. Compress valve springs using Valve Spring Compressor Set 303-350 (T89P-6565-A) and Valve Spring Compressor Set 303-300 (T87C-6565-A) and remove valve spring retainer keys, valve spring retainers and valve springs.
CAUTION: If cylinder head valve components are to be reused, mark position of valve components to verify that they are assembled in their original positions.
3. Remove intake valves and exhaust valves from cylinder heads.
4. Inspect cylinder heads, valve guides, exhaust valve, intake valve, valve springs, valve spring retainers, valve spring retainer keys, camshafts, valve tappets and rocker arms. Replace components as required.
5. Remove valve stem seals using Valve Stem Seal Replacer 303-470 (T94P-6510-CH).
6. Remove valve guides from cylinder heads if necessary upon inspection by using Valve Guide Remover/Replacer 303-346 (T89P-6510-A) by driving valve guides out from the bottom of the cylinder head.
7. Remove pipe plugs and alignment dowels from cylinder heads as necessary to clean cylinder heads.
ASSEMBLY
1. Clean gasket material, dirt and debris from cylinder heads. Wash cylinder heads with a suitable soap and water solution. Dry cylinder heads completely using compressed air.
WARNING: EYE PROTECTION IS REQUIRED TO BE WORN DURING USE OF COMPRESSED AIR. FAILURE TO WEAR EYE PROTECTION COULD RESULT IN POSSIBLE PERSONAL INJURY.
NOTE: Clean cylinder head gasket surface with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. If gasket material remains on cylinder head after cleaning, use a Teflon tipped scraper or hardwood scraper to remove remaining material.
2. If removed, install pipe plugs and alignment dowels to cylinder heads. Apply Pipe Sealant with Teflon D8AZ- 19554-A or equivalent meeting Ford specification WSK-M2G350-A2 and ESR-MI8P7-A to pipe plugs prior to installation. Tighten pipe plugs as follows:
- 1/4-inch pipe plug-Tighten in two steps. Step 1 Tighten to 14 Nm (123 inch. lbs.). Step 2 Tighten an additional 180 degrees.
- 1-inch pipe plug - 80-100 Nm (59-73 ft. lbs.)
3. If removed, install valve guides into cylinder heads using Valve Guide Remover/Replacer 303-346 (T89P-6510-A). Lubricate valve guides and install by driving valve guides into cylinder heads from top of cylinder heads.
4. Using Valve Stem Seal Replacer 303-470 (T34P-6510-CH), install valve stem seals onto cylinder head valve guides.
5. Lubricate valve stems and guides with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install valves into cylinder heads.
6. Using Valve Spring Compressor Set 303-350 (T89P-6565-A) and Valve Spring Compressor Set 303-300 (T87C-6565-A), install valve springs, valve spring retainers and valve spring retainer keys onto cylinder head and valves.
7. Measure assembled height of valve spring from top of spring seat to underside of valve spring retainer with dividers. Check dividers against a scale. If assembled valve spring height is greater than 39-40 mm (1.535-1.575 inch), install necessary spacers between cylinder head spring seat and valve spring to bring assembled height to 39-40 mm (1.535-1.575 inch).
CAUTION: Do not install valve spring spacers unless necessary. Use of valve spring spacers in excess of recommendations will result in over-stressing valve springs and over-loading camshaft lobes. Over-stressing and over-loading could lead to valve spring breakage and/or worn camshaft lobes.