Cylinder Heads

If a cylinder head (6049) is to be replaced, follow the procedures under Cylinder Head Disassembly and Assembly and transfer all valves, valve springs (6513) , spark plugs (12405) , etc., to the new cylinder head . Clean and inspect all parts. Reface valves (refer to Section 03-00). Check all assembly clearances before assembling the new or used parts to the new cylinder head .

Removal

1. Remove the upper intake manifold (9424) and throttle body (9E926) as an assembly. Remove the lower intake manifold .

2. Remove the valve covers (6582) .

   If the LH cylinder head is to be removed on a vehicle with an air conditioner, isolate and remove the A/C compressor (19703) . Refer to Group 12.

   If the LH cylinder head is to be removed, disconnect the power steering pump bracket from the LH cylinder head . Position the power steering pump (3A674) out of the way and in a position that will prevent the oil from draining out. Disconnect oil level indicator tube (6754) from exhaust manifold stud.

   Remove secondary air injection manifold tube (9B449) from rear of cylinder heads .

3. If the RH cylinder head is to be removed, remove the generator (GEN) (10346) , secondary air injection pump (9A486) and generator bracket (10A313) from the RH cylinder head as an assembly.

4. Remove fuel line from retainer at front of RH cylinder head .

5. Disconnect the exhaust manifolds (9430) from the dual converter and pipe.

6. Loosen the rocker arm seat bolts so that the rocker arms (6564) can be rotated to the side. Remove the push rods (6565) in sequence so that they may be installed in their original positions.

7. Remove the cylinder head retaining bolts and lift the cylinder head off the cylinder block (6010) . If required, remove the exhaust manifolds to gain access to the lower attaching bolts. Remove and discard the head gasket (6051) .
   
   
   
   

Installation

1. Clean the cylinder head , intake manifold , valve cover and cylinder head gasket surfaces. If the cylinder head was removed for a cylinder head gasket replacement, check the flatness of the cylinder head and cylinder block gasket surfaces. Refer to Section 03-00.

    CAUTION: Cylinder head retaining bolts must be replaced with new bolts, DO NOT REUSE original cylinder head retaining bolts. They are torque-to-yield bolts and cannot be revised or possible engine damage may occur.

2. Position the new head gasket over the cylinder dowels on the cylinder block . Position the cylinder head on the cylinder block and install the attaching bolts. Remove the holding fixtures.

   Refer to the following illustration for the tightening sequence.

3. The cylinder head bolts are tightened in three steps:
   1. Tighten all bolts in sequence to 34-47 Nm (25-35 lb-ft).
   2. Tighten all bolts in sequence to 61-75 Nm (45-55 lb-ft).
   3. Tighten all bolts in sequence an additional 1/4 turn (85-95 degrees).
      
      
      
      

4. If removed, install the exhaust manifolds . Tighten the retaining bolts to 32-43 Nm (26-32 lb-ft).

    CAUTION: Do not attempt to straighten push rods . Replace push rods if they are bent or damaged.

5. Clean the push rods in a suitable solvent. Blow out the oil passage in the push rods with compressed air. Check the ends of the push rods for nicks, grooves, roughness or excessive wear. Visually check the push rods for straightness or check push rod runout with a dial indicator as outlined in Section 03-00. If runout exceeds the maximum limit at any point, discard the push rod .

6. Apply Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESR-M1C159-A and ESB-M1C93-A to both ends of the push rods . Install the push rods in their original positions. Apply Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESR-M1C159-A and ESB-M1C93-A to the valve stem tips.

7. Install the rocker arms . If all original components are installed, a valve clearance adjustment is not necessary. But if any valve train components are replaced, perform a valve clearance adjustment as outlined.

8. Connect the exhaust manifolds at the dual converter and pipe. Tighten nuts to specification. Refer to Section 09-00.

9. If the RH cylinder head was removed, install the generator bracket , secondary air injection pump and generator on the RH cylinder head .

10. Clean the valve covers . Position the valve cover gaskets (6584) . Install valve covers .

11. Install valve cover bolts and tighten to 16-20 Nm (12-15 lb-ft).

12. If the LH cylinder head was removed on a vehicle with an air conditioner, install the A/C compressor . Refer to Group 12.

13. If the LH cylinder head was removed, install the power steering pump bracket and oil level indicator tube .

14. Install secondary air injection manifold tube at rear of cylinder heads .

15. Install the intake manifolds and related parts.