Installation
NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.
NOTE: Lightly oil all bolt and threads before installation. Always use new bolts when installing a cylinder head.
1. CAUTION: Aluminum components gouge easily. Gouges in aluminum components will cause gaskets to leak.
Lay a clean shop rag in lifter valley to catch any gasket particles. Clean cylinder head, intake manifold and cylinder head to block gasket surfaces. After scraping, lift cloth so no gasket material falls into lifter valley. If the cylinder head was removed for a head gasket replacement, check the flatness of the cylinder head and block gasket surfaces.
2. NOTE: Replace alignment dowels if damaged.
Position head gaskets on cylinder block using the dowels for alignment. Make sure gasket is aligned as shown in the illustration.
3. Carefully position cylinder heads on cylinder block.
4. Install new cylinder head retaining bolts and hand tighten.
5. Tighten retaining bolts in sequence as illustrated to 80 Nm (59 ft. lbs.).
6. Back off all bolts a minimum of one full turn (360 degrees).
7. NOTE: When the cylinder head retaining bolts have been tightened using this procedure, it is not necessary to retighten the bolts after extended engine operation. However, the bolts can be checked for tightness if desired.
Retighten the cylinder head retaining bolts in sequence in two tightening steps as follows:
- 45-55 Nm (33-41 ft. lbs.)
- 85-99 Nm (63-73 ft. lbs.)
8. Install intake manifold.
9. Dip each push rod Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A heavy engine oil. Install push rods in their original positions and orientation.
10. Loosely install rocker arm assemblies in original locations. Apply Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A heavy engine oil. Tighten rocker arm fulcrum bolts to 10-12 Nm (8-10 ft. lbs.) while lifter is on base circle of corresponding cam lobe. Final tighten rocker arm fulcrum bolts to 26-38 Nm (20-28 ft. lbs.).
11. CAUTION: Rocker arm fulcrum must be fully seated into cylinder head and push rods must be fully seated in lifter and rocker arm sockets during final tightening.
NOTE: With number one piston at top dead center (TDC) of the exhaust stroke, you can tighten intake rockers of cylinder numbers 1 and 4, and exhaust rockers of cylinder 2 and 5. With the crankshaft rotated so number one piston is 135° after top dead center (ATDC) of the exhaust stroke, you can tighten intake rockers of cylinder numbers 2, 3, 5 and 6, and exhaust rockers of cylinder numbers 1, 3, 4 and 6.
NOTE: If the original valve train components are being reused, a valve clearance check is not required.
You must check rocker arm to valve tip clearance if a cam, lifters, push rods, rocker arms, rocker arm fulcrums or valves are replaced, or valves are ground.
12. Install valve covers.
13. Install exhaust manifolds. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.). Install inlet pipe retaining nuts, tighten to 39-42 Nm (30-32 ft. lbs.).
14. Apply Cup Plug Sealer meeting Ford specification ESE-M4621-A or equivalent to cylinder block. Install oil level indicator tube into cylinder block. Oil level indicator tube must bottom out as illustrated. Tighten oil level indicator tube retaining nut at exhaust manifold stud bolt to 16-20 Nm (12-14 ft. lbs.)
15. Install fuel charging wiring to fuel injectors and inboard rocker arm cover studs. Connect fuel charging wiring to engine control sensor wiring and secure with retaining features.
16. Install throttle body and new intake manifold gasket.
17. If left cylinder head was removed, perform the following:
a. Install three bolts securing power steering pump support bracket to front of left cylinder head, finger tight only.
b. Install stud bolt at left side of power steering pump support bracket. Tighten all five bolts securing power steering pump support bracket to engine block and cylinder head to 40-62 Nm (30-46 ft. lbs.).
c. Install fuel line retaining bracket to stud bolt on left side of power steering pump support bracket and secure with.nut. Tighten nut to 16-20 Nm (12-15 ft. lbs.).
18. If right cylinder head was removed, perform the following:
a. Install generator (GEN) and generator bracket assembly. Tighten three retaining bolts to 48 Nm (35 ft. lbs.).
b. Install generator brace and tighten huts to 26-35 Nm (20-25 ft. lbs.).
c. Connect generator voltage regulator wiring.
19. A/C system:
a. Position A/C compressor and hose assembly on power steering pump support bracket. Install 4 bolts securing A/C compressor to power steering pump support bracket and tighten four fasteners to 21-29 Nm (15-21 ft. lbs.).
b. Remove plugs and caps from all openings in the air conditioning system.
c. Connect liquid line at condenser and suction hose to accumulator.
d. Evacuate and recharge A/C system.
20. Install engine accessory drive belt.
21. Install ignition coil and bracket assembly to throttle body stud bolts and pencil brace at exhaust manifold. Tighten three nuts to 16-20 Nm (12-14 ft. lbs.).
22. Connect fuel lines to fuel injection supply manifold. Install fuel tube clips.
23. Connect upper radiator hose and heater water hoses. Tighten hose clamps securely.
24. Connect vacuum lines to premarked locations.
25. NOTE: Engine coolant is corrosive to all engine bearing material. Replacing engine oil after removal of a coolant-carrying component prevents failure later.
Drain and change engine oil.
26. Install air cleaner outlet tube to throttle body and engine air cleaner (ACL).Tighten clamps securely.
27. Install closure hose at air cleaner outlet tube and valve cover.
28. CAUTION: This engine has aluminum components and requires a special corrosion-inhibiting coolant formulation to avoid radiator damage.
Fill and bleed cooling system.
29. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Connect ground cable at battery.
30. Start engine and check for coolant, fuel, oil, vacuum and exhaust leaks.
31. Verify base ignition timing.
32. Check and if necessary, Adjust speed control linkage.