Removal and Installation

SPECIAL SERVICE TOOL(S) REQUIRED

Removal

1. Remove engine from vehicle as outlined.

2. Remove valve covers as outlined.

3. Remove engine front cover as outlined.

4. Remove intake manifold as outlined.

5. Remove crankshaft position sensor pulse wheel.

6. Remove rocker arms as outlined.

7. Remove exhaust manifolds as outlined.

8. Drain engine coolant from cylinder block. Refer to Cooling System. Cooling System

9. NOTE: The timing marks on the primary camshaft sprockets must be on the top side of the cam sprockets as shown.

Rotate engine to No. 1 top dead center (TDC).






Crankshaft Location






10. Install Camshaft Positioning Tool T93P-6256-A in rear D-slots of camshafts.

11. Remove bolts retaining RH and LH primary timing chain tensioners to cylinder heads and remove timing chain tensioners.

12. Remove LH and RH primary timing chains, timing chain tensioner arms and timing chain guides. Do not loosen the camshaft timing sprocket retaining bolts.











13. Remove one nut and two bolts retaining inlet heater water hose to rear of RH cylinder head.











14. Remove outlet heater water hose retaining stud bolts from rear of RH cylinder head.






15. Using removal sequence, loosen and remove 10 cylinder head-to-cylinder block retaining bolts on cylinder head to be removed.

16. Discard all removed cylinder head bolts.

17. NOTE: Cylinder heads must not be set on head face if valves are open, as damage may occur.

Remove cylinder heads.

18. Remove head gaskets and discard.

Installation

1. NOTE: Make sure that all bolt holes are clean and dry. Remove engine coolant residue prior to reassembly.

Clean cylinder head, intake manifold, valve cover and cylinder block sealing surfaces. If necessary to check cylinder head and cylinder block flatness, refer to Engine. Engine

2. NOTE: This ensures that all pistons are below top of cylinder block deck face.






Rotate crankshaft counterclockwise as shown.

3. Inspect cylinder head face surface for scratches near coolant passage and combustion chambers.

4. Position new head gaskets on cylinder block.

5. NOTE: Take care not to score the surface of the cylinder head face.

Position LH cylinder head on cylinder block dowels.

6. CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.

NOTE: Apply clean engine oil meeting Ford specification ESE-M2C153-E to all cylinder head bolt threads and both sides of washer on head bolt prior to installation.






Install LH cylinder head bolts. Tighten LH cylinder head bolts as follows:

a. Tighten 10 bolts, in sequence, to 37-43 Nm (27-32 lb-ft).
b. Rotate 10 bolts, in sequence, 85-95°.
c. Rotate 10 bolts, in sequence, an additional 85-95°.

7. Position RH cylinder head on cylinder block dowels.

8. CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.

NOTE: Apply clean engine oil meeting Ford specification ESE-M2C153-E to all cylinder head bolt threads and both sides of washer on head bolt prior to installation.

Install LH cylinder head bolts. Tighten RH cylinder head bolts as follows:

a. Tighten 10 bolts, in sequence, to 37-43 Nm (27-32 lb-ft). Refer to illustration following Step 6.
b. Rotate 10 bolts, in sequence, 85-95°.
c. Rotate 10 bolts, in sequence, an additional 85-95°.

9. Position outlet heater water hose on RH cylinder head. Install and tighten stud bolts to 20-30 Nm (15-22 lb-ft).

10. Position inlet heater water hose on RH cylinder head. Install and tighten one nut and two bolts to 8-12 Nm (71-106 lb-in).

11. Install primary timing chains and set valve timing as outlined.
12. Install rocker arms as outlined.

13. Install crankshaft position sensor pulse wheel.

14. Install intake manifold as outlined.

15. NOTE: When cleaning sealing surfaces of the engine front cover and oil pan-to-cylinder block joints, use extreme caution not to damage the rubber bead of the oil pan gasket. If a leak should occur upon reassembly, remove the oil pan and replace the oil pan gasket.

Install engine front cover as outlined.

16. Install valve covers as outlined.

17. Install exhaust manifolds as outlined.

18. Install engine as outlined.

19. Start engine and check for leaks.

20. Check and add engine oil meeting Ford specification ESE-M2C153-E as needed.