Removal and Installation
REMOVAL
1. Drain engine cooling system.
2. Disconnect battery ground cable.
3. Remove air cleaner outlet tube from throttle body.
4. Loosen drive belt tensioner. Remove drive belt.
5. If LH cylinder head is being removed, perform the following:
a. Remove oil filler cap.
b. Remove power steering pump front mounting bracket retaining bolts.
c. Remove Generator (GEN) and belt idler pulley.
d. Remove power steering pump/generator bracket retaining bolts.
Leaving hoses connected, place pump/bracket assembly aside in a position to prevent fluid from leaking out.
6. If RH cylinder head is being removed, perform the following:
a. Remove drive belt.
b. If equipped with A/C, remove mounting bracket retaining bolts. Leave hoses connected and position A/C compressor aside. If not equipped with A/C, remove A/C belt idler pulley.
c. Remove Positive Crankcase Ventilation valve (PCV valve).
7. Remove upper intake manifold.
8. Remove valve cover.
9. Remove fuel injection supply manifold.
10. Remove lower intake manifold.
11. Remove exhaust manifolds.
12. Loosen rocker arm seat retaining bolts enough to allow rocker arm to be lifted off the push rod and rotate to one side.
13. Remove push rods. Identify position of each push rod. Push rods should be installed in their original position during assembly.
14. Remove cylinder head retaining bolts and discard.
15. Remove cylinder heads.
16. Remove and discard old head gaskets.
17. If disassembling cylinder heads, refer to Disassembly and assembly, Cylinder Head.
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 with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
2. Position new cylinder heads onto cylinder block using cylinder head to block dowels for alignment.
3. Position cylinder heads onto cylinder block.
4. Tighten cylinder head retaining bolts in sequence in three steps as follows:
a. Tighten to 20 Nm (15 ft. lbs.).
b. Tighten to 40 Nm (29 ft. lbs.).
c. Tighten to 50 Nm (36 ft. lbs.).
d. Loosen retaining bolts one at a time, two to three revolutions, and retighten as follows:
Long bolts:
- Tighten to 40-50 Nm (29-37 ft. lbs.).
- Rotate an additional 180 degrees.
- Go to next bolt in sequence.
Short bolts:
- Tighten to 20-30 Nm (15-22 ft. lbs.).
- Rotate an additional 180 degrees.
- Go to next bolt in sequence.
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.
- 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 following 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 Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G 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 Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
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 in. lbs.).
12. Install upper intake manifold.
13. Install spark plugs, 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.
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.