Steps 1 - 50
INSTALLATIONCylinder Heads
Special Tools And Equipment, Part 1:
Special Tools And Equipment, Part 2:
Special Tools
Material:
Material
1. CAUTION: Make sure all coolant residue and foreign material is cleaned from the block surface and the cylinder bore.
CAUTION: The gasket sealing surfaces on the cylinder head and the 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 gaskets ability to seal properly. Do not scratch the gasket.
NOTE: RH shown, LH similar.
Install the head gaskets 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 inch) across a 38.1 mm (1.5 inch) square area.
CAUTION: The gasket sealing surfaces on the cylinder head and the 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.
Tighten the LH cylinder head bolts in 6 stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).
^ Stage 3: Back out 1 full turn (360 degrees).
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees (1/4 turn).
^ Stage 6: Tighten an additional 90 degrees (1/4 turn).
3. 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 inch) across a 38.1 mm (1.5 inch) square area.
CAUTION: The gasket sealing surfaces on the cylinder head and the 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.
Tighten the RH cylinder head bolts in 6 stages in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).
^ Stage 3: Back out 1 full turn (360 degrees).
^ Stage 4: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 5: Tighten an additional 90 degrees (1/4 turn).
^ Stage 6: Tighten an additional 90 degrees (1/4 turn).
4. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Install the hydraulic lash adjusters in their original locations.
5. Using new gaskets, install the RH exhaust manifold. Tighten the nuts in the sequence shown to 20 Nm (15 ft. lbs.).
6. Install the RH exhaust manifold heat shield and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
7. Inspect the O-ring seals. Install new seals if necessary.
8. NOTE: Lubricate the O-ring seals with clean coolant.
Install the coolant tube and the nut.
^ Tighten to 10 Nm (89 inch lbs.).
9. NOTE: Lubricate the O-ring seal with clean engine oil.
Install the oil level indicator tube and the retaining bolt.
^ Tighten to 10 Nm (89 inch lbs.).
10. Using new gaskets, install the LH exhaust manifold. Tighten the nuts in the sequence shown to 20 Nm (15 ft. lbs.).
11. Install the LH exhaust manifold heat shield and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
12. CAUTION: Prior to installation, inspect the tensioner sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
NOTE: The following 2 steps must be performed on both hydraulic chain tensioners.
Compress the tensioner plunger, using a vise.
13. Install a retaining clip on the LH tensioner to hold the plunger in during installation.
14. 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.
15. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and/or valve damage will occur.
Using the special tool, position the crankshaft.
16. Install the crankshaft sprocket, make sure the timing mark faces forward.
17. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install and tighten the bolts to 10 Nm (89 inch lbs.).
3 Position the RH timing chain guide.
4 Install and tighten the bolts to 10 Nm (89 inch lbs.).
18. 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 120 o'clock position.
19. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
20. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the LH timing chain on the camshaft sprocket. Make sure the copper colored link aligns with the camshaft sprocket timing mark.
21. 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 and the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
22. Remove the retaining clip from the LH timing chain tensioner.
23. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
24. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the RH timing chain on the camshaft sprocket. Make sure the copper colored link aligns with the camshaft sprocket timing mark.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
26. Remove the retaining clip from the RH timing chain tensioner.
27. As a post check, verify correct alignment of all timing marks.
28. Install the crankshaft sensor ring on the crankshaft.
29. NOTE: If the bolts are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant alone the head to block surface as specified.
30. Install new engine front cover gaskets on the engine front cover. Position the engine front cover. Install the fasteners finger tight.
31. Tighten the front cover bolts and stud bolts in the sequence shown to 25 Nm (18 ft. lbs.).
32. Lubricate the front cover and the front oil seal inner lip with clean engine oil.
33. Using the special tool, install the front oil seal into the engine front cover.
34. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
35. Using the special tool, install the crankshaft pulley.
36. NOTE: Use special tool 303 D055 to hold the crankshaft pulley.
Install the bolt and washer. Tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
37. Rotate the camshaft until the lobe is in the upward position.
38. Install the special tool between the valve spring coils to prevent valve stem seal damage.
39. Use the special tool to compress the valve spring and install the camshaft roller followers.
40. Install the spark plugs.
^ Tighten to 18 Nm (13 ft. lbs.).
41. Inspect the LH valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
42. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the valve cover.
43. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the left valve cover gasket surface, in 2 places, where the engine front cover meets the cylinder head.
44. Install the left valve cover and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
45. Inspect the RH valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
46. If a new gasket is being installed, apply instant gel adhesive completely around the gasket Groove in the valve cover.
47. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the right valve cover gasket surface, in 2 places, where the engine front cover meets the cylinder head.
48. Install the right valve cover and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
49. Install the RH engine support insulator bracket and the bolts.
^ Tighten to 72 Nm (53 ft. lbs.).
50. Install new intake manifold gaskets.