Installation
1. Clean cylinder head, intake manifold, valve cover and head gasket surfaces. If cylinder head was removed for head gasket replacement, check flatness of cylinder head and cylinder block gasket surfaces.
NOTE:
- RH and LH head gaskets are not interchangeable.
- Lightly oil all bolts and stud bolt threads before installation except those specifying special sealant.
2. Position new cylinder heads onto cylinder blocks (6010) using cylinder head to block dowels (6A008) for alignment.
3. Position cylinder heads onto cylinder blocks.
4. Tighten cylinder head retaining bolts in numerical sequence in three steps as follows:
step 1: 20 Nm (15 ft. lbs.).
step 2: 40 Nm (30 ft. lbs.).
step 3: 50 Nm (37 ft. lbs.).
Loosen retaining bolts one at a time two to three revolutions and retighten as follows:
CAUTION: Do not loosen all of the bolts at the same time; only work on one bolt at a time or damage to engine or leakage may occur.
Long bolts:
Tighten to 40-50 Nm (30-37 ft. lbs.).
Rotate an additional 175-185 degrees.
Go to next bolt in sequence.
Short bolts:
Tighten to 20-30 Nm (15-22 ft. lbs.).
Rotate an additional 175-185 degrees.
Go to next bolt in sequence.
CAUTION: Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface area.
NOTE: When cylinder head retaining bolts have been tightened using the above procedure, it is not necessary to retighten bolts after extended engine operation. However, bolts can be checked for tightness if desired.
5. Dip each push rod end in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install push rods in their original positions.
NOTE: If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check.
6. Lubricate all rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
7. Install rocker arms.
8. Install exhaust manifolds.
9. Install lower intake manifold.
10. Install fuel injection supply manifold.
11. Position rocker arm and new valve cover on cylinder head and install retaining bolts. Note location of ignition wire routing clip stud bolts. Tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).
12. Install upper intake manifold.
13. Install spark plugs (12405), if removed.
14. Connect ignition wires to the spark plugs.
15. If LH cylinder head is being installed, perform the following:
(a) Install oil filler cap.
(b) Install generator/power steering pump mounting bracket.
(c) Install generator.
(d) Install accessory drive belt tensioner.
(e) Install power steering pump (3A674).
(f) Install power steering pump support bracket.
16. If RH cylinder head is being installed, perform the following:
(a) Install positive crankcase ventilation valve.
(b) If equipped with A/C, install A/C compressor mounting and supporting brackets. Install A/C compressor.
17. Install drive belt.
18. Connect battery ground cable.
19. Install air cleaner outlet tube.
20. Fill engine cooling system with specified coolant.
CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibited coolant formulation to avoid cooling system damage.
21. Start engine and check for coolant, fuel and oil leaks.