Part 1
All Vehicles
1. 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: 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 0.0254 mm (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. Tighten the cylinder head bolts in six stages, in the sequence shown.
- Stage 1: Tighten bolts to 40 Nm (30 lb-ft).
- Stage 2: Tighten bolt an additional 90 degrees (1/4 turn).
- Stage 3: Loosen the bolts a minimum of one full turn (360 degrees).
- Stage 4: Tighten bolts to 40 Nm (30 lb-ft).
- Stage 5: Tighten bolts an additional 90 degrees (1/4 turn).
- Stage 6: Tighten bolts an additional 90 degrees (1/4 turn).
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.
LH Cylinder Head
6. NOTE: Lubricate the O-ring seal with clean engine oil.
Install the oil level indicator tube.
- Install a new O-ring seal on the oil level indicator tube.
7. Install the LH exhaust manifold.
- Install a new exhaust manifold gasket.
- Install the LH exhaust manifold.
- Tighten the nuts in the sequence shown.
RH Cylinder Head
8. Install the RH exhaust manifold.
- Install a new exhaust manifold gasket.
- Install the RH exhaust manifold.
- Tighten the nuts in the sequence shown.
Engines With Ratcheting Timing Chain Tensioners
9. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
NOTE: LH shown, RH similar.
Compress each tensioner plunger, using an edge of a vise.
10. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
11. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
12. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
- Remove the tensioner from the vise.
13. 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.
14. Using the special tool, position the crankshaft.
- Remove the special tool after crankshaft positioning.
15. Install the crankshaft sprocket, making sure the flange faces forward.
16. Install the timing chain guides.
- Position the LH timing chain guide.
- Install and tighten the LH bolts.
- Position the RH timing chain guide.
- Install and tighten the RH bolts.
17. 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.
18. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
19. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
20. 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.
21. Remove the retaining clip from the LH timing chain tensioner.
22. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
23. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
24. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
25. Remove the retaining clip from the RH timing chain tensioner.
26. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
27. Rotate the camshaft until the lobe is in the up position.
28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
29. NOTE: Lubricate the camshaft roller followers using clean engine oil.
Install the camshaft roller followers.
- Install the special tool.
- Compress the valve spring.
- Install the camshaft roller followers in their original locations.
30. Remove the special tool.
31. Install all eight spark plugs.
32. Install the crankshaft sensor ring.
33. 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 and the oil pan-to-block surface as specified.
34. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
35. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
36. Loosely install the bolts, then tighten the bolts in two stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
37. Install the RH engine mount.
38. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
39. Using the special tools, install the front oil seal.
40. NOTE: If not secured within four minutes, 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 sealant to the Woodruff key slot on the crankshaft pulley.
41. Using the special tools, install the crankshaft pulley.
42. NOTE: Use special tool 303-009 or suitable strap wrench to hold the pulley.
Tighten the crankshaft pulley bolt in four stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Rotate an additional 90 degrees (1/4 turn).
43. Position the coolant pump pulley on the water pump and install the bolts.
44. Install the accessory drive belt idler pulley.
45. NOTE: If not secured within four minutes, 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 sealant in two places where the engine front cover meets the cylinder head.
46. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
47. NOTE: If not secured within four minutes, 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 sealant in two places where the engine front cover meets the cylinder head.