Part 1
Special Tool(s)
Material
All Cylinder Heads
1. CAUTION: The gasket sealing surfaces on the cylinder head and 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 gaskets ability to seal correctly. Do not scratch the gasket.
NOTE: The RH head gasket is shown; the LH head gasket is 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 in) across a 38.1 mm (1.5 in) square area.
CAUTION: The gasket sealing surfaces on the cylinder head and 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.
NOTE: The RH cylinder head is shown; the LH cylinder head is similar.
Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
LH Cylinder Head
3. NOTE: Make sure to tighten the bolts in sequence in three stages.
Tighten the LH bolts in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90°.
- Stage 3: Tighten an additional 90°.
RH Cylinder Head
4. NOTE: Make sure to tighten the bolts in the following three stages.
Tighten the RH bolts in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90°.
- Stage 3: Tighten an additional 90°.
All Cylinder Heads
5. Remove the special tools from both ends of the cylinder head.
6. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Install the hydraulic lash adjusters in their original locations.
RH Cylinder Head
7. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
LH Cylinder Head
8. NOTE: Lubricate the 0-ring seal with clean engine oil.
Install the oil level indicator tube.
- Install a new 0-ring seal on the oil level indicator tube.
- Install the oil level indicator tube.
- Install the bolt.
9. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
All Cylinder Heads
10. CAUTION: The timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Compress the tensioner plunger, using an edge of a vise.
11. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
12. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
13. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
14. Remove the tensioner from the vise.
15. 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.
16. Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the LH bolts.
3. Position the RH timing chain guide.
4. Install and tighten the RH bolts.
17. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
18. CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and valve damage can occur.
NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
Using the special tool, position the crankshaft so the number one cylinder is at TDC.
19. Remove the Crankshaft Holding Tool.
20. NOTE: The crankshaft sprockets are identical. They may only be installed one way. Refer to the following illustration for the correct crankshaft sprocket installation.
If removed, install the LH and the RH crankshaft sprockets.
21. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
22. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
23. 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.
24. Remove the retaining clip from the LH timing chain tensioner.
25. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
26. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
27. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
28. Remove the retaining clip from the RH timing chain tensioner.
29. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
30. Install the special tool between the valve spring coils to prevent valve stem seal damage.
31. NOTE: Lubricate the camshaft roller followers using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
Install the camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.
32. Remove the special tool.
33. CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.
Install the eight spark plugs.
- Tighten the spark plugs to 18 Nm (13 lb-ft).
34. Install the crankshaft sensor ring on the crankshaft.
35. NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
36. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.