Cylinder Head Assembly: Service and Repair

Removal
1. Remove the lower intake manifold.
2. Remove the LH valve cover.
3. Remove the RH valve cover.
4. Remove the exhaust manifold.





5. If removing the LH cylinder head, position the power steering pump reservoir aside.
1 Remove the bolts.
2 Position the power steering reservoir aside.
6. If removing the LH cylinder head and, if equipped, remove the A/C compressor.





7. If removing the LH cylinder head, remove and support the A/C compressor mounting bracket and power steering pump.
1 Remove the bolts.
2 Remove the nuts.
3 Loosen the remaining (A) bolt until the (B) A/C compressor mounting bracket and power steering pump are free from the LH cylinder head. Support the A/C compressor mounting bracket and power steering pump and position aside.





8. If removing the LH cylinder head, disconnect the Cylinder Head Temperature (CHT) sensor and the knock sensor electrical connectors.
9. If removing the RH cylinder head, remove the Generator (GEN).





10. If removing the RH cylinder head, remove the idler pulley.
1 Remove the bolt.
2 Remove the idler pulley.





11. If removing the RH cylinder head, remove the generator mounting bracket.
1 Remove the bolts.
2 Remove the generator mounting bracket.





12. CAUTION: If the components are to be reinstalled, they must be installed in the same position. Mark the components for location.

Remove the six rocker arms.
1 Remove the bolts.
2 Remove the rocker arms.





13. Remove the push rods.





14. Note: Discard the cylinder head bolts.

Note: Record the location of the long and the short bolts.

Remove the cylinder head.
- Remove and discard the bolts.


Installation
1. Clean and inspect the cylinder head for flatness.





2. Position a new cylinder head gasket and install the cylinder head.





3. CAUTION: Always use new bolts.

Note: Lubricate bolts with clean Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install new bolts. Refer to the location note made during removal and make sure the bolts are installed in the correct location.
1 Install the new long bolts.
2 Install the new short bolts.





4. Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten the bolts to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten the bolts to 40 Nm (30 ft. lbs.).
- Stage 3: Tighten the bolts to 50 Nm (37 ft. lbs.).





5. CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened and final-tightened prior to working on the next bolt in the sequence.

Note: The short bolts are numbered 2, 4, 6 and 8 and the long bolts numbered 1, 3, 5 and 7. Tighten the bolts in the sequence shown in four stages:
- Stage 1: Tighten the short bolts to 25 Nm (18 ft. lbs.).
- Stage 2: Tighten an additional 180°.
- Stage 3: Tighten the long bolts to 45 Nm (33 ft. lbs.).
- Stage 4: Tighten an additional 180°.






6. CAUTION: Refer to the location note made during removal and make sure the components are installed in the correct location.

Note: Lubricate the pushrods with clean Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

Install the pushrods.





7. Install the rocker arms, tighten the bolts in two stages.
- Stage 1: Tighten the bolts to 5 Nm (44 inch lbs.).
- Stage 2: Tighten the bolts to 35 Nm (26 ft. lbs.).
8. If valve train components have been replaced, inspect the valve clearance.





9. If installing the RH cylinder head, install the generator mounting bracket.
1 Position the generator mounting bracket.
2 Install the long bolts.
3 Install the short bolt.





10. If installing the RH cylinder head, install the idler pulley.
1 Position the idler pulley.
2 Install the bolt.
11. If installing the RH cylinder head, install the generator.





12. If installing the LH cylinder head, install the A/C compressor mounting bracket and power steering pump.
1 Position the A/C compressor mounting bracket and power steering pump.
2 Start the bolt.
3 Install the bolts.
4 Install the nuts.





13. Connect the Cylinder Head Temperature (CHT) sensor and the knock sensor electrical connectors.
14. If installing the LH cylinder head, install the A/C compressor (if equipped).





15. If installing the LH cylinder head, install the power steering fluid reservoir.
1 Position the power steering fluid reservoir.
2 Install the bolts.
16. Install the exhaust manifolds.

17. Note: Inspect the LH valve cover gasket for damage. Install a new gasket, if necessary.

Install the LH valve cover.

18. Note: Inspect the RH valve cover gasket for damage. Replace if necessary.

Install the RH valve cover.
19. Install the lower intake manifold.