Cylinder Heads

Removal

1. Drain engine cooling system as outlined in Section 03-03.

2. Disconnect battery ground cable (14301).

3. Remove air cleaner outlet tube (9B659) from throttle body (9E926).

4. Loosen drive belt tensioner (6B209). Remove drive belts (8620) .

5. If LH cylinder head (6049) is being removed, perform the following:
   1. Remove oil filler cap (6766).
   2. Remove power steering pump front mounting bracket retaining bolts.
   3. Remove generator (GEN) (10346) and belt idler pulley (8678) .
   4. Remove power steering pump/generator bracket retaining bolts.

      Leaving hoses connected, place pump/bracket assembly aside in a position to prevent fluid from leaking out.

6. If RH cylinder head is being removed, perform the following:
   1. Remove drive belt .
   2. If equipped with A/C, remove mounting bracket retaining bolts. Leave hoses connected and position A/C compressor (19703) aside. If not equipped with A/C, remove A/C idler pulley.
   3. Remove positive crankcase ventilation valve (PCV valve) (6A666) .

7. Remove upper intake manifold (9424) .

8. Remove valve cover (6582).

9. Remove fuel injection supply manifold (9F792).

10. Remove lower intake manifold as outlined.

11. Remove exhaust manifolds (9430) as outlined.

12. Loosen rocker arm fulcrum retaining bolts enough to allow rocker arm (6564) to be lifted off the push rod (6565) and rotate to one side.

13. Remove push rods. Identify position of each push rod . Push rods should be installed in their original position during assembly.

14. Remove cylinder head retaining bolts and discard.

15. Remove cylinder heads .

16. Remove and discard old head gaskets (6051) .

17. If disassembling cylinder head(s), refer to Cylinder Head, Disassembly.

Installation

NOTE: Lightly oil all bolts and stud bolt threads before installation except those specifying special sealant.

1. Clean cylinder head, intake manifold , rocker arm cover and head gasket surfaces. If cylinder head was removed for head gasket replacement, check flatness of cylinder head and cylinder block (6010) gasket surfaces. Refer to Section 03-00 for procedure.

2. Position new head gasket(s) onto cylinder block using dowels for alignment.
   
   
   
   

3. Position cylinder heads onto cylinder block .

    CAUTION: Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface area.

   NOTE: When cylinder head retaining bolts have been tightened using the following procedure, it is not necessary to retighten bolts after extended engine operation. However, bolts can be checked for tightness if desired.

4. Tighten cylinder head retaining bolts in sequence as follows:
   1. 20 Nm (15 lb-ft).
   2. 40 Nm (29 lb-ft).
   3. 50 Nm (37 lb-ft).

       CAUTION: Do not loosen all of the bolts at the same time; only work on one bolt at a time.

   4. Back off retaining bolts one at a time two to three revolutions and retighten as follows:

      Long bolts:

      • Tighten to 15-25 Nm (11-19 lb-ft).
      • Rotate an additional 85-95 degrees.
      • Go to next bolt in sequence.

      Short Bolts:

      • Tighten to 10-20 Nm (7-15 lb-ft).
      • Rotate an additional 85-95 degrees.
      • Go to next bolt in sequence.
      
      
      
      
      
      

      Item	Part Number	Description
      1	6010	Cylinder Block
      2	—	Locating Pin (2 Req'd)
      3	N802515-S	Cylinder Head Bolt (4 Req'd Each Side)
      4	6049	Cylinder Head
      5	N802516-S	Cylinder Head Bolt (4 Req'd Each Side)
      6	6A008	Cylinder Head to Block Dowel

5. Dip each push rod end in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

   NOTE: If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check. Refer to Section 03-00.

   Install push rods in their original position.

6. Lubricate all rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

7. Install rocker arms as outlined.

8. Install exhaust manifolds as outlined.

9. Install lower intake manifold as outlined.

10. Install fuel injection supply manifold .

11. Position rocker arm and new valve cover on cylinder head and install retaining bolts. Note location of ignition wire routing clip stud bolts. Tighten retaining bolts to 9-12 Nm (7-9 lb-ft).

12. Install upper intake manifold.

13. Install spark plugs (12405), if removed. Tighten to 9-20 Nm (7-15 lb-ft).

14. Connect ignition wires to the spark plugs.

15. If LH cylinder head is being installed, perform the following:
    1. Install oil filler cap.
    2. Install generator/power steering pump mounting bracket.
    3. Install generator .
    4. Install accessory drive belt tensioner.
    5. Install power steering pump (3A674) .
    6. Install power steering pump support bracket. Section 11-02 for torque specifications.

16. If RH cylinder head is being installed, perform the following:
    1. Install positive crankcase ventilation valve .
    2. If equipped with A/C, install A/C compressor mounting and supporting brackets. Install A/C compressor.

17. Install drive belt and tighten to specification. Refer to Section 03-05.

18. Connect battery ground cable.

19. Install air cleaner outlet tube as outlined in Section 03-12.

     CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibited coolant formulation to avoid cooling system damage. Refer to Section 03-03 for the coolant specifications.

20. Fill engine cooling system with specified coolant.

21. Start engine and check for coolant, fuel and oil leaks.