Part 1 of 2

Cylinder Heads








Special Tool(s)





Material





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.





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.

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 (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 ft. lbs.).
5. Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
6. Stage 6: Tighten the bolts an additional 90 degrees (1/4 turn).





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 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.

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 (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 ft. lbs.).
5. Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
6. Stage 6: Tighten the bolts an additional 90 degrees (1/4 turn).





4. Install the hydraulic lash adjusters in their original locations.





5. Using new gaskets, install the RH exhaust manifold. Tighten the nuts in the sequence thrown





6. Install the RH exhaust manifold heat shield and the bolts.





7. Inspect the O-ring seals. Install new seals if necessary.





8. Install the coolant tube and the nut.





9. NOTE: Lubricate the O-ring seal with clean engine oil.

Install the oil level indicator tube and the retaining bolt.





10. Using new gaskets, install the LH exhaust manifold. Tighten the nuts in the sequence shown.





11. Install the LH exhaust manifold heat shield and the bolts.

CAUTION: The timing chain procedures must be followed exactly or damage to the valves and pistons will result.





12. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

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





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





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





15. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
16. Remove the tensioner from the vise.





17. 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.








18. Position the crankshaft with the special tool.





19. Install the crankshaft sprocket, make sure the timing mark faces forward.
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. 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.





22. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.





23. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.





24. 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.





25. Remove the LH retaining pin from the timing chain tensioner.





26. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.





27. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.





28. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.





29. Remove the RH retaining pin from the timing chain tensioner.





30. 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.





31. Position the crankshaft sensor ring on the crankshaft.





32. 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.





33. Using new gaskets, install the engine front cover. Install the fasteners finger-tight.








34. Tighten the front cover bolts and stud bolts in the sequence shown.