Part 1

Cylinder Heads

Special Tool(s):

Special Tool(s):

Material:

Installation (Steps 1-43)

Both 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 gasket's ability to seal correctly. Do not scratch the gasket.

NOTE: RH head gasket shown, LH head gasket similar.





Install the new 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 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: RH cylinder head shown, LH cylinder head similar.





Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.





3. Tighten the cylinder head bolts in 6 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).
^ Stage 3: Loosen a minimum of one full turn (360 degrees).
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees (1/4 turn).
^ Stage 6: Tighten an additional 90 degrees (1/4 turn).





4. Remove the special tools from both ends of the cylinder head.

5. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.





Install the hydraulic lash adjusters in their original locations.

LH cylinder head

6. NOTE: Lubricate the 0-ring seal with clean engine oil.





Install a new 0-ring seal on the oil level indicator tube and install the oil level indicator tube and bolt.
^ Tighten to 10 Nm (89 inch lbs.).





7. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 nuts.
^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown.

RH cylinder head





8. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 nuts.
^ Tighten to 25 Nm (18 ft. lbs.) in the sequence shown.

Engines with ratcheting timing chain tensioners

9. CAUTION: 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.

NOTE: LH shown, RH similar.





Compress each tensioner plunger, using an edge of a vise.





10. Using a small screwdriver or pick, push back and hold the ratchet mechanism.





11. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





12. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
^ Remove the tensioner from the vise.

Engines with non-ratcheting timing chain tensioners

13. CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body or permanent compression of the seal bead, will require replacement of the tensioner.

Inspect the RH and LH timing chain tensioners.
^ Install new tensioners as necessary.

14. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

NOTE: LH shown, RH similar.





Compress each tensioner plunger, using an edge of a vise.





15. Install a retaining clip on the tensioner to hold the plunger in during installation.

Both cylinder heads





16. 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.





17. Using the special tool, position the crankshaft.
^ Remove the special tool after crankshaft positioning.





18. Install the crankshaft sprocket, making sure the flange faces forward.





19. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install and tighten the LH bolts to 10 Nm (89 inch lbs.).
3 Position the RH timing chain guide.
4 Install and tighten the RH bolts to 10 Nm (89 inch lbs.).





20. 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.





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 on the dowel pin and install the LH timing chain tensioner.
^ Tighten to 25 Nm (18 ft. lbs.).





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.
^ Tighten to 25 Nm (18 ft. lbs.).





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. Rotate the camshaft until the lobe is in the upward position.





31. Install the special tool between the valve spring coils to prevent valve stem seal damage.

32. 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 follower.
1 Install the special tool.
2 Compress the valve spring.
3 Install the camshaft roller followers in their original location.





33. Remove the special tool.





34. Install all 8 spark plugs.
^ Tighten to 15 Nm (11 ft. lbs.).





35. Install the crankshaft sensor ring.

36. NOTE: If the engine front cover is not secured within 4 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 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.





Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.





37. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.








38. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).





39. Loosely install the bolts, then tighten in 2 stages in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.

40. NOTE: RH shown, LH similar.





Install the RH and LH engine mounts and the bolts.
^ Tighten to 70 Nm (52 ft. lbs.).





41. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.





42. Using the special tools, install the front oil seal.

43. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.





Apply sealant to the Woodruff key slot on the crankshaft pulley.