Part 1

Cylinder Heads

1. CAUTION: The gasket sealing surface on the cylinder head and 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 correctly. Do not scratch the gasket.

NOTE: RH head gasket shown; LH head gasket similar.






Install the head gasket 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 O.O2Mmm (0.001 in) across a 38.1 mm (1.5 in) square area.

CAUTION: The gasket sealing surfaces on the cylinder head and 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.

NOTE: RH cylinder head shown; LH cylinder head similar.






Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.

3. NOTE: LH shown, RH similar.






Tighten the bolts in six stages in the sequence shown.

- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Tighten an additional 90°.

- Stage 3: Loosen the bolts a minimum of one full turn.

- Stage 4: Tighten to 40 Nm (30 lb-ft).

- Stage 5: Tighten an additional 90°.

- Stage 6: Tighten an additional 90°.






4. Remove the special tools from both ends of the cylinder head.

5. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.






Install the hydraulic lash adjusters in their original locations.

6. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons can result.

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

NOTE: LH shown; RH similar.






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






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






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






9. Install a paper clip into the hole of each tensioner housing to hold in the ratchet assembly and plunger during installation.

10. Remove the tensioner from the vise.






11. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.






12. Install the timing chain guides.

1. Position LH timing chain guide.

2. Install and tighten the bolts.

3. Position the RH timing chain guide.

4. Install and tighten the RH bolts.





13. 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.

14. CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and valve damage can occur.

NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.






Using the special tool, position the crankshaft so the number one cylinder is at TDC.

15. Remove the special tool.

16. NOTE: The crankshaft sprockets are identical. They can be installed only one way.






Refer to the illustration for crankshaft sprocket installation. Install the LH and RH crankshaft sprockets.






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






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

19. 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.






20. Remove the retaining clip from the LH timing chain tensioner.






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






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






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






24. Remove the retaining clip from the RH timing chain tensioner.






25. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.






26. Install the crankshaft sensor ring on the crankshaft.

27. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.






Apply a bead of sealant along the head-to-block surface as shown.






28. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.











29. Tighten the front cover fasteners in the sequence shown.






30. Loosely install the bolts, then tighten the bolts in three stages in the sequence shown.

- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 20 Nm (15 lb-ft).

- Stage 3: Tighten an additional 60°.






31. Install the accessory belt idler pulleys.






32. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.







33. Using the special tool, install the front oil seal.






34. Install the coolant pump pulley and bolts.