Cylinder Head

Removal

If the cylinder head (6049) is to be replaced, refer to Cylinder Head under Subassemblies in the Disassembly and Assembly portion of this section. Transfer all valves, springs, etc., to the new cylinder head. If these are worn, the complete head assembly may have to be replaced. Clean and inspect all parts, reface the valves and check valve guide clearances before assembling the used parts to the new cylinder head. Refer to Section 03-00.

1. Drain the cooling system and the crankcase. Remove the air cleaner outlet tube (9B659). Remove A/C compressor (19703) and A/C condenser core (19712). Refer to Section 03-05 and to the applicable section in Group 12.

2. Disconnect the battery ground cable (14301). Disconnect the heater water hose (18472) from the water pump (8501) and water outlet connection.

3. Disconnect the fuel lines from the fuel injection supply manifold (9D280) with Fuel Line Removal Tool T93T-9550-AH.

4. Disconnect transmission oil cooler lines and remove the radiator (8005). Refer to Section 03-03.

5. Remove the cooling fan, drive belt idler bracket (8A610), water pump pulley (8509) and drive belt (8620). Refer to Section 03-05.

6. Remove accelerator control splash shield (9E766) and disconnect the accelerator cable (9A758), transmission kickdown cable (C6 only), and speed control actuator cable (9A825) at the throttle body.

7. Disconnect the power brake vacuum line at the intake manifold vacuum outlet fitting and cap (9A474).

8. Disconnect the exhaust manifolds (9430) from the dual converter Y pipe (5F250). Disconnect the battery ground cable at the engine (6007).

9. Disconnect the engine gauge feed wire (14289) from the powertrain control module (PCM) (12A650).

10. Disconnect the engine control sensor wiring (12A581) and fuel charging wiring (9D930) and related connectors. Position the harnesses out of the way.

11. Remove the generator mounting bolts and position the generator (GEN) (10300) out of the way, leaving the wires attached. Remove the secondary air injection pump (AIR pump) (9A486) from generator mounting bracket (10153). Remove the generator mounting bracket from engine.

12. Remove power steering pump (3A674) from the A/C compressor mounting bracket (2882) and position it right side up and to one side, leaving the lines attached. If equipped with A/C compressor, discharge the system and recover refrigerant. Refer to Section 12-00. Disconnect the A/C manifold and tube (19D734) at the A/C compressor mounting bracket. Remove A/C compressor from A/C compressor mounting bracket. Remove the A/C compressor mounting bracket from engine.

13. Remove the upper intake manifold (9424).

14. Remove the valve cover (6582). Loosen the rocker arm bolts so that the rocker arms (6564) can be rotated to one side. Refer to Valve Cover and Gasket and to Rocker Arm in the In-Vehicle service portion of this section.

15. Remove the push rods (6565) in sequence and identify them so that they can be installed in their original positions.

16. Disconnect the distributor to spark plug wires at the spark plugs (12405) using Spark Plug Wire Remover T74P-6666-A.

    

17. Remove the cylinder head bolts.

18. Install the cylinder head lifting eyes using Engine Lifting Bracket T70P-6000.

19. Position a floor crane and attach the hoist and lifting sling to the lifting eyes using Rotunda Universal Load Positioning Sling 014-00036 and Rotunda Floor Crane 014-00133 or equivalents.

20.  CAUTION: Do not pry between the cylinder head and cylinder block (6010) as the gasket surfaces may become damaged.

    Lift the cylinder head and lower intake manifold and exhaust manifold assemblies off the engine.

21. Gently tapping the cylinder head using a heavy plastic or rawhide hammer will help free up the cylinder head and ease removal.

22. Remove secondary air injection manifold (9B445) and secondary air injection check valve (9A487).

    

Installation

1. Clean the cylinder head and cylinder block gasket surfaces. Clean the exhaust manifold and dual converter Y pipe gasket surfaces.

2. Check the flatness of the cylinder head and cylinder block gasket surfaces. Refer to Section 03-00.

3. Install secondary air injection manifold and secondary air injection check valve (if removed).

4. Position the head gasket (6051) over the cylinder head to block dowels (6A008) on the cylinder block.

5. Install lifting eyes on the cylinder head and use a floor crane and lifting sling to lift the cylinder head over the cylinder block. Lower it carefully until it is properly positioned on the cylinder block and cylinder head to block dowels. Remove the hoist and lifting eyes.

6. NOTE: Inspect cylinder head bolt for stretch. If stretch is found, replace cylinder head bolts.

   Coat the threads of the cylinder head bolts with engine oil. Install the bolts.

7. NOTE: When cylinder head bolts have been tightened, it is not necessary to retighten the bolts after extended operation.

   Tighten the bolts in the numerical sequence shown. Bolts are tightened in two steps.

   • Tighten all bolts in numerical sequence to 61-74 Nm (45-55 lb-ft).
   • Rotate all bolts in numerical sequence an additional 80-100 degrees.

   Cylinder Head Bolts Tightening Sequence

   

8. Apply Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A to both ends of the push rods. Install the push rods in their original bores, positioning the lower end of the push rod in the valve tappet sockets.

9. Install valve cover and related parts. Refer to Valve Cover and Gasket and to Rocker Arm in the In-Vehicle Service portion of this section.

10. Install the upper intake manifold.

11. Connect the distributor to spark plug wires to the correct spark plugs.

12. Install the dual converter Y pipe lockwashers and nuts. Tighten the nuts 34-49 Nm (25-36 lb-ft).

13. NOTE: When the battery (10655) has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

    Connect battery to starter relay cable (14300) engine ground connections.

14. Connect engine control sensor wiring and fuel charging wiring and related connectors.

15. Connect engine gauge feed wire to powertrain control module.

16. Connect the brake vacuum line to the intake manifold.

17. Route and connect engine control sensor wiring and fuel charging wiring.

18. Install generator mounting bracket on engine and tighten bolts and nuts to 30-40 Nm (22-30 lb-ft).

19. Install secondary air injection pump on generator mounting bracket and tighten bolts to 30-40 Nm (22-30 lb-ft).

20. Install generator to bracket and tighten top bolt to 22-28 Nm (16-21 lb-ft). Tighten outside bolt to 53-72 Nm (40-53 lb-ft).

21. Install A/C compressor mounting bracket to engine and tighten nuts to 54-71 Nm (40-53 lb-ft). Tighten two bolts to 30-40 Nm (22-30 lb-ft).

22. Install A/C compressor and power steering pump brace, if equipped, and tighten bolts to 30-40 Nm (22-30 lb-ft).

23. If not equipped with air conditioning, install power steering pump brace and tighten bolts to 24-31 Nm (18-23 lb-ft).

24. Install power steering pump with assembled hoses and tighten bolts to 40-55 Nm (30-40 lb-ft).

25. Install the water pump pulley, fan clutch (8A616), fan and drive belt. Tighten the fan bolts to 16-24 Nm (12-18 lb-ft).

26. Install the radiator. Connect the lower radiator hose (8286) to the water pump and the upper radiator hose (8260) to the water outlet connection. Install A/C condenser core.

27. On a vehicle with an automatic transmission, connect the oil cooler lines.

28. Connect battery ground cable to battery.

29. Fill and bleed the cooling system. Refer to Section 03-03. Fill the crankcase with oil specified in Section 00-03. Operate the engine at fast idle and check all hose connections and gaskets for leaks.

30. Perform Quick Test to check the function of the PCM system. Refer to Powertrain Control/Emissions Diagnosis Manual OBDII.

31. On a vehicle with standard transmission, check for correct clutch operation.

32. On a vehicle with an automatic transmission, refer to Section 07-01A (E4OD), Section 07-01B (C6) or Section 07-01C (4R70W). Check the fluid level and add as required to bring it to the proper level on the fluid level indicator (7A020).