Removal and Installation
REMOVAL1. Disconnect battery ground cable (14301).
2. Remove intake manifold (9424).
3. Raise and support vehicle.
NOTE: The front lower bolt on power steering pump (3A674) will not come all the way out.
4. Remove bolts retaining power steering pump to engine.
5. Position power steering pump out of the way and secure with wire.
6. Remove crankshaft pulley (6312).
7. Remove four oil pan-to-engine front cover retaining bolts.
8. Disconnect three way catalytic converters (TWC)(5E212) from RH and LH exhaust manifolds (9430).
9. Lower exhaust system and secure to crossmember with wire as shown.
10. Remove retainer for starter motor wiring harness from rear of cylinder head (6049).
11. Lower vehicle.
12. Remove two RH ignition coil bracket retaining bolts, two nuts and one bolt retaining LH ignition coil bracket. Remove ignition coil brackets and ignition coils (12029) as an assembly.
13. Remove water pump pulley (8509).
14. Disconnect positive battery cable at power distribution box and harness (14516).
15. Remove retaining bolt from positive battery cable on the side of cylinder head. Position positive battery cable out of way.
16. Disconnect evaporative emission return tube (9G271) from evaporative emission canister.
17. Remove evaporative emission return tube from RH valve cover stud.
18. Remove RH valve cover retaining bolts and stud bolts. Remove RH valve cover (6582).
19. Remove LH valve cover retaining bolts and stud bolts. Remove LH valve cover.
20. Remove air conditioning high pressure line retaining nut from front cover assembly stud bolt.
21. Remove eight stud bolts and seven bolts retaining engine front cover (6019) to cylinder block (6010). Remove engine front cover.
22. Remove timing chains.
NOTE: The lower rear bolt cannot be removed due to interference with the power brake booster (2005). Use a rubber band or similar item to hold bolt away from cylinder block as shown.
LH Lower Rear Head Bolt Removal:
23. Remove ten bolts retaining LH cylinder head to cylinder block.
CAUTION: Cylinder head must not be set on head face. If valves are open, damage to the engine may occur.
24. Remove LH cylinder head.
25. Remove ground strap retaining nut and ground strap from RH cylinder head.
26. Remove bolt and nut retaining heater tube to RH cylinder head.
NOTE: The lower rear bolt cannot be removed due to interference with A/C evaporator housing (19850). Use a rubber band or similar item to hold bolt away from cylinder block as shown.
27. Remove 10 bolts retaining RH cylinder head to cylinder block.
28. Remove RH cylinder head.
29. If cylinder heads are to be replaced and/or serviced, see Disassembly and Reassembly. Disassembly and Assembly
INSTALLATION
1. Clean cylinder head, intake manifold, valve cover and cylinder block sealing surfaces under Disassembly and Assembly. If necessary check cylinder head and cylinder block flatness.
NOTE: This makes sure that all pistons (6108) are below top of cylinder block deck face.
2. Rotate crankshaft (6303) counterclockwise 45°.
3. Inspect cylinder head face surface for scratches near coolant passage and combustion chambers.
4. Rotate camshaft (6250) to a stable position where valves do not extend below cylinder head face.
5. Position new head gaskets (6051) on cylinder block.
CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.
6. Install lower rear cylinder head bolts and retain in position with rubber bands or similar items.
NOTE: Take care not to score the surface of the cylinder head face.
7. Position LH cylinder head on cylinder head to block dowels (6A008).
8. Apply clean engine oil meeting Ford specification WSS-M2C910-A1 to all head bolt spot-faces.
9. Remove rubber band from lower rear bolt and install nine remaining bolts. Hand-tighten.
10. Tighten LH cylinder head bolts in six steps as follows:
a. Tighten 10 bolts, in sequence, to 37-43 Nm (28-31 ft. lbs.).
b. Rotate 10 bolts, in sequence, 85-95°.
c. Loosen 10 bolts, in sequence, a minimum of 360°.
d. Tighten 10 bolts, in sequence, to 37-43 Nm (28-31 ft. lbs.)
e. Tighten 10 bolts, in sequence, 85-95°.
f. Tighten 10 bolts, in sequence, an additional 85-95°.
11. Position RH cylinder head on cylinder head to block dowel.
12. Apply clean engine oil meeting Ford specification WSS-M2C910-A1 to all head bolt spot-faces.
13. Remove rubber band from lower rear bolt and install the nine remaining bolts. Hand-tighten.
14. Tighten RH cylinder head bolts in six steps as follows:
a. Tighten 10 bolts, in sequence, to 37-43 Nm (28-31 ft. lbs.).
b. Tighten 10 bolts, in sequence, 85-95°.
c. Loosen 10 bolts, in sequence, a minimum of one full turn 360°.
d. Tighten 10 bolts, in sequence, to 37-43 Nm (28-31 ft. lbs.).
e. Tighten 10 bolts, in sequence, 85-95°.
f. Tighten 10 bolts, in sequence, an additional 85-95°.
15. Position heater water hose (18472) on cylinder head and install bolt and nut. Tighten to 8-12 Nm (71-106 inch lbs.).
16. Install ground strap on RH cylinder head. Tighten retaining nut to 8-12 Nm (71-106 ft. lbs.).
17. Rotate camshafts using flats matched at center of camshaft until both are in time and install Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A on flats of camshaft. This will prevent the camshafts from rotating.
CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as TDC.
NOTE: This will position crankshaft at TDC No 1.
18. Rotate crankshaft clockwise 45°.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and/or pistons will result.
19. Install timing chains.
20. Install engine front cover.
21. Install valve covers.
22. Raise and support vehicle.
23. Position starter motor wiring harness to rear of cylinder head and install retainer.
24. Connect three way catalytic converters to RH and LH exhaust manifolds.
25. Position power steering pump to cylinder block and install retaining bolts. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).
26. Lower vehicle.
27. Install intake manifold.
28. Connect battery ground cable.
29. Check and add clean engine oil meeting Ford specification WSS-M2C910-A1.
30. Start engine and inspect for leaks.