Removal and Installation
CAUTION:Aluminum Components
Do not work on aluminum engine components until the engine is cold.
Cleaning Aluminum Surfaces
Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.
Removing Aluminum Components
When removing engine components, always remove retaining bolts in reverse of tightening sequence or damage to engine components may occur.
Interference Type Engine
This is NOT a free-wheeling engine, if it has jumped time, there will be damage to the valves and pistons (6108) and will require the removal of the cylinder heads.
Valve/Piston Damage
The camshaft sprockets (6256) should only be disassembled from the camshafts when one of the components is to be replaced. At no time, when the timing chain(s) are removed and the cylinder heads (6049) are installed, may the crankshaft (6303) and camshafts (6250) be rotated. Failure to follow these directions will result in valve and/or piston damage.
REMOVAL
1. Disconnect battery ground cable (14301).
2. Drain cooling system and remove fan blade (8600) and fan shroud (8146).
3. Relieve fuel system pressure and disconnect fuel lines. Refer to Powertrain Management.
4. Remove air cleaner outlet tube (9B659). Refer to Powertrain Management.
5. Remove windshield wiper governor (17C476).
6. Release drive belt tensioner (6B209) and remove accessory drive belts (8620).
CAUTION: Do not pull on ignition wire as wires may separate from the connector in the ignition wire boot.
7. Disconnect ignition wires from spark plugs (12405).
8. Disconnect ignition wires and ignition wire separators (12297) from valve cover stud bolts.
9. Disconnect engine control sensor extension wire (12A522) from both ignition coils (12029) and camshaft position sensor (CMP)(6B288).
10. Remove bolts retaining power steering oil reservoir (3A697) to the LH ignition coil bracket and position out of the way.
11. Remove three nuts retaining RH ignition coil bracket to engine front cover (6019).
12. Remove LH ignition coil and ignition wires as an assembly.
13. Remove four nuts retaining LH ignition coil bracket to engine front cover.
14. Slide ignition coil brackets and ignition wire and bracket (12280) assembly off mounting studs and remove from vehicle.
15. Remove water pump pulley (8509).
16. Disconnect generator wiring harness from junction block, front fender apron (16054) and generator (GEN)(10346).
17. Remove two bolts retaining generator mounting bracket (10153) to intake manifold (9424).
18. Remove two bolts retaining generator to cylinder block (6010) and remove generator (GEN)(10300).
19. Disconnect and remove positive crankcase ventilation valve (PCV valve)(6A666) from valve cover (6582).
20. Disconnect 42-pin engine harness connector and 8-pin connector leading to the mass air flow sensor (MAF)(12B579).
21. Remove nut retaining A/C line to the RH front fender apron.
22. Lift A/C line and feed the fuel charging wiring 42-pin connector under the A/C line. Position fuel charging wiring (9D930) out of the way.
23. Disconnect the engine control sensor extension wire from the crankshaft position sensor (CKP)(6C315), A/C clutch (2884) and evaporative emission canister purge valves (EVAP canister purge valve)(9C915).
24. Raise and support vehicle.
NOTE: The front lower bolt on the power steering pump (3A674) will not come all the way out.
25. Remove bolts retaining power steering pump to cylinder block and engine front cover.
26. Secure the power steering pump out of the way.
27. Remove oil pan (6675) and oil pan gasket (6710).
28. Remove crankshaft pulley bolt (6A340) and crankshaft pulley retaining washer (6378) from crankshaft (6303).
29. Install Crankshaft Damper Remover T58P-6316-D on crankshaft pulley (6312) and pull crankshaft pulley from crankshaft.
30. Disconnect the engine control sensor extension wire from the electronic variable orifice sensor and oil pressure sensor (9278).
31. Position engine control sensor extension wire out of the way.
32. Disconnect EGR valve to exhaust manifold tube (9D477) from RH exhaust manifold (9430).
33. Disconnect three way catalytic converter (TWC)(5E212) from RH and LH exhaust manifolds.
34. Lower exhaust system and secure to crossmember in positions shown with wire.
35. Remove bolt retaining starter wiring harness to rear of RH cylinder head (6049).
36. Lower vehicle.
37. Remove bolts and stud bolts retaining RH valve cover to cylinder head and remove valve cover.
38. Disconnect accelerator cable (9A758) and speed control actuator cable (9A825).
39. Remove accelerator cable bracket (9723) from intake manifold and position out of the way.
40. Remove bolts and stud bolts retaining LH valve cover to cylinder head and remove valve cover.
41. Disconnect vacuum hose from throttle body adapter vacuum port.
42. Disconnect engine control sensor extension wire from heated oxygen sensors (HO2S)(9F472).
43. Disconnect heater water hose (18472).
NOTE: Two water outlet connection retaining bolts also retain intake manifold.
44. Remove two bolts retaining water hose connection (8592) to intake manifold and position upper radiator hose (8260) and water hose connection out of the way.
45. Remove the remaining nine bolts retaining intake manifold to cylinder heads and remove intake manifold.
46. Remove intake manifold gaskets (9461).
47. Remove engine front cover. Follow proper procedure.
48. Remove timing chains. Follow proper procedure.
NOTE: Cylinder head must not be set on head face. If valves are open damage may occur.
49. Remove 10 bolts retaining LH cylinder head to cylinder block and remove LH cylinder head.
50. Remove the two bolts retaining heater water hose to LH cylinder head.
51. Remove 10 bolts retaining RH cylinder head to cylinder block and remove RH cylinder head.
52. If cylinder heads are to be replaced or serviced refer to Disassembly and Assembly. Disassembly and Assembly
INSTALLATION
1. Clean cylinder head, intake manifold, valve cover and cylinder block sealing surfaces. If necessary, check cylinder head and cylinder block flatness.
NOTE: This step makes sure that all pistons (6108) are below top of cylinder block deck face.
2. Rotate crankshaft counterclockwise 45°. Keyway will be at 9 o'clock position.
3. Inspect cylinder head face surface for scratches near coolant passage and combustion chambers.
4. Rotate camshaft to a stable position where valves do not extend below cylinder head face.
5. Position new head gasket (6051) on cylinder block.
CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.
NOTE: Take care not to score the surface of the cylinder head face.
6. Position LH cylinder head on cylinder head to block dowels (6A008).
7. Apply clean engine oil meeting Ford specification WSS-M2C153-F to all head bolt spot-faces.
8. Remove rubber band from lower rear bolt and install nine remaining bolts. Hand tighten.
9. Tighten ten LH cylinder head bolts as follows:
Step 1 ... Tighten head bolts in sequence to 37-43 Nm (28-31 ft. lbs.).
Step 2 ... Rotate head bolts in sequence, 85-95°.
Step 3 ... Loosen head bolts a minimum of one full turn (360)°.
Step 4 ... Retighten head bolts in sequence to 37-43 Nm (28-31 ft. lbs.).
Step 5 ... Rotate head bolts in sequence 85-95°.
Step 6 ... Rotate head bolts in sequence an additional 85-95°.
10. Position RH cylinder head on cylinder head to block dowels.
11. Apply clean engine oil meeting Ford specification WSS-M2C153-F to all head bolt spot-faces.
12. Install the ten remaining bolts. Hand-tighten.
13. Tighten RH cylinder head bolts using Steps 1 through 6 above.
14. Position heater water hose on LH cylinder head and install two bolts. Tighten lower retainer bolt to 8-12 Nm (71-106 inch lbs.) and upper retaining bolt to 20-30 Nm (15-22 ft. lbs.).
CAUTION: Timing chain procedures must be followed exactly or damage to valves or pistons will result.
15. Install timing chains. Follow proper procedure.
16. Install crankshaft position sensor pulse wheel.
17. Inspect and replace crankshaft front seal (6700) engine front cover gasket (6020) and replace as necessary.
18. Clean engine front cover sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.
19. Apply a 8-12 mm (0.32-0.47 inch) bead of Silicone Gasket and Sealant in locations shown.
20. Install engine front cover on engine.
21. Install stud bolts and bolts retaining engine front cover to engine. Tighten to 20-30 Nm (15-22 ft. lbs.).
22. Inspect intake manifold for nicks and cuts. Replace intake manifold as required.
NOTE: Make sure alignment tabs on intake manifold gaskets are aligned with holes in cylinder heads.
23. Position new intake manifold gaskets on cylinder heads.
24. Position intake manifold on cylinder heads.
25. Install and tighten intake manifold retaining bolts one through nine in sequence shown in the illustration to 20-30 Nm 15-22 ft. lbs.).
26. Install water thermostat (8575) and new O-ring, then position water hose connection and upper radiator hose and install two bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).
27. Connect heater water hose.
28. Connect engine control sensor extension wire to heated oxygen sensors.
29. Connect vacuum hose to throttle body adapter vacuum port.
NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner to remove all residues that may interfere with the sealer's ability to adhere.
30. Apply Silicone Gasket and Sealant at both places engine front cover meets cylinder head.
31. Position and, using Gasket and Trim Adhesive F3AZ-193508-B or equivalent meeting Ford specifications ESR-M11P17A and ESE-M2G52-A, secure new valve cover gaskets (6584) into valve covers and install valve covers onto cylinder heads.
32. Install bolts and stud bolts into RH valve cover. Tighten all bolts and stud bolts to 8-12 Nm (71-106 inch lbs.).
33. Install bolts and stud bolts into LH valve cover. Tighten all bolts and stud bolts to 8-12 Nm (71-106 inch lbs.).
34. Install accelerator cable bracket on intake manifold and connect accelerator cable and speed control actuator cables to throttle body (9E926).
35. Raise and support vehicle.
36. Position starter wiring harness to RH cylinder head and install retaining bolt.
37. Remove wire and position three way catalytic converter to RH and LH exhaust manifolds.
NOTE: Make sure exhaust system clears No.3 crossmember. Adjust as necessary.
38. Install four exhaust manifold to dual converter and pipe nuts and tighten to 27-41 Nm (20-30 ft. lbs.).
39. Connect EGR valve to exhaust manifold tube to RH exhaust manifold and tighten nut to 35-45 Nm (26-33 ft. lbs.).
40. Connect engine control sensor extension wire to the electronic variable orifice sensor and oil pressure sensor.
NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner to remove all residues that may interfere with the sealer's ability to adhere.
41. Apply Silicone Gasket and Sealant in keyway of crankshaft pulley as shown.
42. Position crankshaft pulley on crankshaft. Make sure crankshaft key and keyway are aligned.
43. Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley.
44. Install crankshaft pulley bolt and crankshaft pulley retaining washer. Tighten in four steps:
Step 1 ... Tighten to 90 Nm (66 ft. lbs.).
Step 2 ... Loosen one complete turn (360°).
Step 3 ... Tighten to 50 Nm (36 ft. lbs.).
Step 4 ... Tighten an additional 90°.
45. Install oil pan with new oil pan gasket. Follow proper procedure.
46. Position power steering pump on engine and install four retaining bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).
47. Lower vehicle.
48. Connect fuel charging wiring to the A/C clutch, crankshaft position sensor and evaporative emission canister purge valve.
49. Position and connect 42-pin engine harness connector and 8-pin connector.
50. Position A/C line and install retaining nut.
51. Install positive crankcase ventilation valve in RH valve cover.
52. Connect front evaporative emission hose to evaporative emission canister purge valve.
53. Position generator and install two retaining bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).
54. Install two bolts retaining generator rear mounting bracket to intake manifold and tighten to 8-12 Nm (71-106 inch lbs.).
55. Install water pump pulley and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
56. Position ignition coil brackets, ignition wires and ignition wire separator onto mounting stud bolts.
57. Install nuts retaining ignition coil brackets to engine front cover. Tighten to 20-30 Nm (15-22 ft. lbs.).
58. Install LH ignition coil and ignition wire assembly.
59. Connect engine control sensor extension wire to both ignition coils and camshaft position sensor.
60. Position and install power steering oil reservoir.
61. Connect ignition wires to spark plugs and install ignition wire separators onto valve cover studs.
62. Install accessory drive belt.
63. Install windshield wiper governor.
64. Connect fuel lines.
65. Install cooling fan motor/fan blade and fan shroud assembly. Fill engine cooling system.
66. Install air cleaner outlet tube. Refer to Powertrain Management.
67. Connect battery ground cable.
68. Check and add clean engine oil as needed.
69. Start engine and check for leaks.