Installation

All cylinder heads

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: The RH head gasket is shown, the LH head gasket is similar.

Install the head gasket over the dowel pins.

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.

2. NOTE: The RH cylinder head is shown; the LH cylinder head is similar.

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

LH Cylinder Head

3. NOTE: Make sure to tighten the bolts in sequence in three stages.

Tighten the LH bolts in the sequence shown.

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

- Stage 2: Tighten an additional 90°.

- Stage 3: Tighten an additional 90°.

RH Cylinder Head

4. NOTE: Make sure to tighten the bolts in the following three stages.

Tighten the RH bolts in the sequence shown.

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

- Stage 2: Tighten an additional 90°.

- Stage 3: Tighten an additional 90°.

Both Cylinder Heads

5. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil. Install the hydraulic lash adjusters in their original locations.

RH Cylinder Head

6. Install the RH exhaust manifold.

- Install a new RH exhaust manifold gasket.

- Install the RH exhaust manifold.

- Tighten the nuts in the sequence shown.

Both Cylinder Heads

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

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

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

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

9. while holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

10. Install a paper clip into the hose in the tensioner housing to hold the ratchet assembly. Remove the tensioner from the vise.

11. NOTE: There are 61 links in the timing chain.

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

12. Install the timing chain guides.

13. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is approximately in the 11 o'clock position.

14. Using the special tool, position the crankshaft.

15. Remove the special tool.

16. NOTE: Crankshaft sprockets are identical. They may only be installed one way.

If removed, install the LH and RH crankshaft sprockets.

1. Timing marks aligned.

2. Keyways aligned.

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

18. Install the LH timing chain onto the camshaft sprocket, aligning the two copper (marked) links with the timing mark 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 paper clip from the LH timing chain tensioner.

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

22. Install the RH timing chain onto the camshaft sprocket, aligning the two copper (marked) links with the timing mark on the sprocket.

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

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

25. Verify the camshaft and crankshaft sprocket to copper link alignment.

26. Position the piston of the cylinder being repaired at the bottom of the stroke and the camshaft lobe at the base.

27. Using the special tool, compress the intake valve springs and install the roller followers in their original location.

28. Using the special tool, compress the exhaust valve springs and install the roller followers in their original location.

29. Repeat the previous three steps to install all the roller followers.

30. Position the crankshaft sensor ring on the crankshaft.

31. 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 silicone gasket sealant in the locations shown.

32. Position the engine front cover and install the bolts and the studs in three stages:

- Stage 1: Tighten numbers one through five to 25 Nm (18 lb-ft).

- Stage 2: Tighten numbers six and seven to 50 Nm (37 lb-ft).

- Stage 3: Tighten numbers 11 through 15 to 25 Nm (18 lb-ft).

33. Loosely install the bolts, then tighten in two stages in the sequence shown.

- Stage 1: Tighten to 20 Nm (15 lb-ft).

- Stage 2: Tighten an additional 90°.

34. NOTE: If the valve covers are 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 silicone gasket sealant in the locations shown.

35. NOTE: If the valve covers are 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.

NOTE: LH shown, RH similar.

Install the valve covers and the bolts in the sequence shown.

36. NOTE: LH shown RH similar.

Install the eight spark plugs.

37. Install the bolt and the belt idler pulley.

38. Lubricate the front oil seal and the engine front cover with clean engine oil.

39. Using the special tools, install the front crank seal.

40. NOTE: If 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 silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

41. Using the special tool, install the crankshaft pulley.

42. NOTE: Use a suitable strap wrench to hold the pulley while tightening the bolt.

Install the bolt and washer. Tighten the bolt in four stages:

- Stage 1: Tighten to 90 Nm (66 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 50 Nm (37 lb-ft).

- Stage 4: Tighten an additional 90°.