Part 1
Cylinder HeadsPart 1 Of 2:
Part 2 Of 2:
Special Tool(s)
Material
1. CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.
NOTE: RH shown, LH similar.
Install the head gasket over the dowel pins.
2. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.
CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean..
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.
Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
3. Tighten the LH cylinder head bolts in six stages in the sequence shown.
1 Stage 1: Tighten the bolts to 40 Nm (30 ft. lbs.).
2 Stage 2: Tighten the bolts an additional 90 degrees.
3 Stage 3: Loosen the bolts a minimum of one full turn.
4 Stage 4: Tighten to 40 Nm (30 ft. lbs.).
5 Stage 5: Tighten an additional 90 degrees.
6 Stage 6: Tighten an additional 90 degrees.
4. Tighten the RH cylinder head bolts in six stages in the sequence shown.
1 Stage 1: Tighten the bolts to 40 Nm (30 ft. lbs.).
2 Stage 2: Tighten the bolts an additional 90 degrees.
3 Stage 3: Loosen the bolts a minimum of one full turn.
4 Stage 4: Tighten to 40 Nm(30 ft. lbs.).
5 Stage 5: Tighten an additional 90 degrees.
6 Stage 6: Tighten an additional 90 degrees.
5. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Install the hydraulic lash adjusters in their original locations for both cylinder heads.
6. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
NOTE: LH shown, RH similar.
Compress each tensioner plunger, using an edge of a vise.
7. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
8. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
9. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
10. Remove the tensioner from the vise.
11. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
12. Install the timing chain guides.
13. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is approximately at the 11 o'clock position.
14. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Using the special tool, position the crankshaft.
^ Remove the special tool.
15. Install the crankshaft sprocket with the flange facing forward.
16. Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
17. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
18. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
19. Remove the retaining clip from the LH timing chain tensioner.
20. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
21. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
22. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
23. Remove the retaining clip from the RH timing chain tensioner.
24. As a post-check, verify correct alignment of all timing marks.
25. Position the piston of the cylinder being repaired at the bottom of the stroke and the camshaft lobe at the base circle.
26. Using the special tool, compress the intake valve spring and install the roller followers in their original locations.
27. Using the special tool, compress the exhaust valve spring and install the roller followers in their original locations.
28. Repeat the above three steps to install all the roller followers.
29. Position the crankshaft sensor ring on the crankshaft.
30. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to do this procedure can result in future oil leakage.
Apply silicone gasket and sealant in the locations shown.
Part 1 Of 2:
Part 2 Of 2:
31. Install the engine front cover and tighten the bolts in the sequence shown.
32. Loosely install the bolts, then tighten in two stages in the sequence shown.
^ Stage 1: Tighten to 20 Nm(15 ft. lbs.).
^ Stage 2: Tighten an additional 60 degrees.
33. NOTE: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to do this procedure can result in future oil leakage.
Apply silicone gasket and sealant in the locations shown.
34. NOTE: RH shown, LH similar.
Install the valve covers and tighten the bolts in the sequence shown.
35. NOTE: LH shown, RH similar.
Install the eight spark plugs.
36. Install the belt idler pulleys.