Part 1
Special Tool(s)
Material
Both Cylinder Heads
1. CAUTION: Make sure all coolant residue and foreign material is cleaned from the block surface and the cylinder bore.
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 properly. Do not scratch the gasket.
NOTE: RH shown, LH similar.
Install the head gaskets over the dowel pins.
LH Cylinder Head
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 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.
Tighten the LH cylinder head bolts in six stages in the sequence shown.
1. Stage 1: Tighten the bolts to 40 Nm (30 lb-ft).
2. Stage 2: Tighten the bolts an additional 90° (1/4 turn).
3. Stage 3: Back out all the bolts one full turn (360°).
4. Stage 4: Tighten the bolts to 40 Nm (30 lb-ft).
5. Stage 5: Tighten the bolts an additional 90° (1/4 turn).
6. Stage 6: Tighten the bo~ an additional 90° (1/4 turn).
RH Cylinder Head
3. 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 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.
Tighten the RH cylinder head bolts in six stages in the sequence shown.
1. Stage 1: Tighten the bolts to 40 Mm (30 lb-ft).
2. Stage 2: Tighten the bolts an additional 90° (1/4 turn).
3. Stage 3: Back out all the bolts one full turn (360 degrees).
4. Stage 4: Tighten the bolts to 40 Nm (30 lb-ft).
5. Stage 5: Tighten the bolts an additional 90° (1/4 turn).
6. Stage 6: Tighten the bolts an additional 90° (1/4 turn).
Both Cylinder Heads
4. Remove the Lifting Handles from both ends of the cylinder head.
5. Install the hydraulic lash adjusters in their original locations.
RH Cylinder Head
6. Using new gaskets, install the RH exhaust manifold. Tighten the nuts in the sequence shown.
7. Install the RH exhaust manifold heat shield.
8. Inspect the O-ring seals. Install new seals if necessary.
9. Install the tube and the nut.
LH Cylinder Head
10. NOTE: Lubricate the O-ring seal with clean engine oil.
Install the oil level indicator tube and the retaining bolt.
11. Using new gaskets, install the LH exhaust manifold. Tighten the nuts in the sequence shown.
12. Install the LH exhaust manifold heat shield.
Both Cylinder Heads
CAUTION: The timing chain procedures must be followed exactly or damage to the valves and pistons will result.
13. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Compress the tensioner plunger, using an edge of a vise.
14. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
15. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
16. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
17. Remove the tensioner from the vise.
18. If the copper links are not visible, mark one link on one end and one link on the other end, and use as the timing marks.
19. Position the crankshaft with the special tool. Remove the special tool after positioning the crankshaft.
20. Install the crankshaft sprocket, make sure the timing mark faces forward.
21. 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.
22. Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the bolts.
3. Position the RH timing chain guide.
4. Install and tighten the bolts.
23. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
24. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
25. 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.
26. Remove the LH retaining pin from the timing chain tensioner.
27. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
28. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
29. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
30. Remove the RH retaining pin from the timing chain tensioner.
31. As a post-check, make sure the copper (marked) links on the timing chains line up with the timing marks on the crankshaft and camshaft sprockets.
32. Position the crankshaft sensor ring on the crankshaft.
33. NOTE: If the bolts are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant along the head-to-block surface and the oil pan-to- cylinder block surface as specified.
34. Using new gaskets, install the engine front cover. Install the fasteners finger tight.
35. Tighten the front cover bolts and stud bolts in the sequence shown.
36. Lubricate the front cover and the front oil seal inner lip with clean engine oil.
37. Using the special tools, install the front oil seal into the engine front cover.
38. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
39. Using the special tool, install the crankshaft pulley.
40. NOTE: Use special tool 303-D055 to hold the crankshaft pulley.
Install the crankshaft pulley bolt and washer. Tighten the bolt in four stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Loosen one full turn (360°).
- Tighten to 50 Nm (37 lb-ft).
- Tighten an additional 90° (1/4 turn).
41. Install the special tool between the valve spring coils to prevent valve stem seal damage.
42. NOTE: Lubricate the camshaft roller followers using clean engine oil.
Rotate the crankshaft until the cam lobe is directly away from the roller follower.
43. NOTE: Install the roller followers into their original locations.
Using the special tool to compress the valve spring, install the camshaft roller followers.
44. Remove the special tool.
45. Install the spark plugs.
46. If a new gasket is being installed, apply adhesive completely around the gasket groove in the LH valve cover.