Cylinder Heads

Item	Specification
Motorcraft Silicone Gasket Remover ZC-30	-
Motorcraft Metal Surface Prep ZC-31	-

1. Remove the engine. For additional information, refer to Engine .
2. Mount the engine on a suitable engine stand.
3. To remove individual components, carry out only the listed steps.
4. Remove the components in the order indicated in the following illustration and table.
   Fig 2: Removing Components (1 Of 20)

   Courtesy of FORD MOTOR CO.
5. Remove the components in the order indicated in the following illustration and table.
   Fig 3: Removing Components (2 Of 20)

   Courtesy of FORD MOTOR CO.
6. Remove the components in the order indicated in the following illustration and table.
   Fig 4: Removing Components (3 Of 20)

   Courtesy of FORD MOTOR CO.
7. Remove the components in the order indicated in the following illustration and table.
   Fig 5: Removing Components (4 Of 20)

   Courtesy of FORD MOTOR CO.
8. Remove the components in the order indicated in the following illustration and table.
   Fig 6: Removing Components (5 Of 20)

   Courtesy of FORD MOTOR CO.
9. Remove the components in the order indicated in the following illustration and table.
   Fig 7: Removing Components (6 Of 20)

   Courtesy of FORD MOTOR CO.
10. Remove the components in the order indicated in the following illustration and table.
    Fig 8: Removing Components (7 Of 20)

    Courtesy of FORD MOTOR CO.
11. Remove the components in the order indicated in the following illustration and table.
    Fig 9: Removing Components (8 Of 20)

    Courtesy of FORD MOTOR CO.
12. Remove the components in the order indicated in the following illustration and table.
    Fig 10: Removing Components (9 Of 20)

    Courtesy of FORD MOTOR CO.
13. Remove the components in the order indicated in the following illustration and table.
    Fig 11: Removing Components (10 Of 20)

    Courtesy of FORD MOTOR CO.
14. Remove the components in the order indicated in the following illustration and table.
    Fig 12: Removing Components (11 Of 20)

    Courtesy of FORD MOTOR CO.
15. Remove the components in the order indicated in the following illustration and table.
    Fig 13: Removing Components (12 Of 20)

    Courtesy of FORD MOTOR CO.
16. Remove the components in the order indicated in the following illustration and table.
    Fig 14: Removing Components (13 Of 20)

    Courtesy of FORD MOTOR CO.
17. Remove the components in the order indicated in the following illustration and table.
    Fig 15: Removing Components (14 Of 20)

    Courtesy of FORD MOTOR CO.
18. Remove the components in the order indicated in the following illustration and table.
    Fig 16: Removing Components (15 Of 20)

    Courtesy of FORD MOTOR CO.
NOTE: The following illustration is for reference only. Removal notes must be followed for removing timing drive components.
Fig 17: Removing Components (16 Of 20)
Courtesy of FORD MOTOR CO.
19. Remove the components in the order indicated in the following illustration and table.
NOTE: The following illustration is for reference only. Removal notes must be followed for removing drive components.
Fig 18: Removing Components (17 Of 20)
Courtesy of FORD MOTOR CO.
20. Remove the components in the order indicated in the following illustration and table.
NOTE: The following illustration is for reference only. Removal notes must be followed for removing drive components.
Fig 19: Removing Components (18 Of 20)
Courtesy of FORD MOTOR CO.
21. Remove the components in the order indicated in the following illustration and table.
22. Remove the components in the order indicated in the following illustration and table.
    Fig 20: Removing Components (19 Of 20)

    Courtesy of FORD MOTOR CO.
23. Remove the components in the order indicated in the following illustration and table.
    Fig 21: Removing Components (20 Of 20)

    Courtesy of FORD MOTOR CO.

ITEMS 1 AND 2: FLANGED PLUG REMOVAL NOTE 

1. Drain the coolant from the engine block.

ITEM 9: COOLANT PUMP PULLEY BOLTS REMOVAL NOTE 

1. Loosen the coolant pump pulley bolts prior to removing the accessory drive bolt.

ITEM 15: COOLANT PUMP PULLEY REMOVAL NOTE 

1. Remove the coolant pump pulley bolts and the coolant pump pulley.

ITEMS 16-18: CRANKSHAFT PULLEY REMOVAL NOTE 

NOTE: Hold the crankshaft pulley with the special tool while removing the bolt and washer.
1. Remove the bolt and washer.
   • Discard the bolt and washer.
     Fig 22: Removing Crankshaft Pulley Bolt & Washer

     Courtesy of FORD MOTOR CO.
2. Using the special tool, remove the crankshaft damper.
   Fig 23: Removing Crankshaft Damper

   Courtesy of FORD MOTOR CO.

ITEM 19: CRANKSHAFT FRONT SEAL REMOVAL NOTE 

1. Using the special tool, remove the crankshaft front seal.
   • Discard the seal.
   Fig 24: Removing Crankshaft Front Seal

   Courtesy of FORD MOTOR CO.

ITEMS 27-30: RH AND LH COIL COVER REMOVAL NOTE 

1. Remove all silicone sealer and residue from the coil covers.
   Fig 25: Removing Silicone Sealer & Residue From Coil Covers

   Courtesy of FORD MOTOR CO.
2. Remove all silicone sealer and residue from the valve cover surface and ignition coil wiring harness.
   Fig 26: Removing Silicone Sealer & Residue From Valve Cover

   Courtesy of FORD MOTOR CO.

ITEMS 41 AND 42: ENGINE COVER SUPPORT BRACKET REMOVAL NOTE 

1. Disconnect the engine wiring harness retainers from the engine cover support bracket.
   Fig 27: Disconnecting Engine Wiring Harness Retainers From Engine Cover Support Bracket

   Courtesy of FORD MOTOR CO.

ITEM 43: ENGINE WIRING HARNESS REMOVAL NOTE 

NOTE: LH is shown, RH is similar.
Fig 28: Disconnecting Engine Wiring Harness Retainers From RH Engine
Courtesy of FORD MOTOR CO.
1. Disconnect the engine wiring harness retainers from the RH engine appearance cover support bracket.
NOTE: LH is shown, RH is similar.
Fig 29: Disconnect Fuel Injector and Radio Interference Capacitor Electrical Connectors
Courtesy of FORD MOTOR CO.
2. Disconnect the fuel injector and radio interference capacitor electrical connectors
NOTE: LH shown, RH similar.
Fig 30: Disconnecting Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
3. Disconnect the ignition coil electrical connectors.
4. Disconnect the EGR system module electrical connector.
5. Remove the nuts and the engine wiring harness retainer and position aside.
   Fig 31: Removing Nuts & Engine Wiring Harness Retainer & Position

   Courtesy of FORD MOTOR CO.
NOTE: RH is shown, LH is similar.
Fig 32: Disconnecting Variable Cam Timing (VCT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
6. Disconnect the variable cam timing (VCT) sensor electrical connector.
7. Disconnect the wiring harness retainers from the LH valve cover.
   Fig 33: Disconnecting Wiring Harness Retainers From LH Valve Cover

   Courtesy of FORD MOTOR CO.
8. Disconnect the three wiring harness retainers from the RH valve cover.
   Fig 34: Disconnecting Three Wiring Harness Retainers From RH Valve Cover

   Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
Fig 35: Disconnecting Pin-Type Retainers
Courtesy of FORD MOTOR CO.
9. Disconnect the pin-type retainers.
10. Disconnect the generator electrical connector.
    Fig 36: Disconnecting Generator Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Remove the wiring harness from the front cover.
    Fig 37: Removing Wiring Harness From Front Cover

    Courtesy of FORD MOTOR CO.
12. Remove the wiring harness from the front cover.
    Fig 38: Removing Wiring Harness From Front Cover

    Courtesy of FORD MOTOR CO.
13. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 39: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Remove the heated oxygen sensor (HO2S) connectors from the brackets.
    Fig 40: Removing Heated Oxygen Sensor (HO2S) Connectors From Brackets

    Courtesy of FORD MOTOR CO.
15. Remove the engine wiring harness from the engine.

ITEM 52: EGR SYSTEM MODULE REMOVAL NOTE 

1. Disconnect the EGR system module-to-exhaust manifold tube from the EGR system module.
   Fig 41: Disconnecting EGR System Module-To-Exhaust Manifold Tube From EGR System Module

   Courtesy of FORD MOTOR CO.

ITEMS 65-67 INTAKE MANIFOLD REMOVAL NOTE 

NOTE: RH is shown, LH is similar.
Fig 42: Removing Nut & Radio Interference Capacitor
Courtesy of FORD MOTOR CO.
1. Remove the nut and the radio interference capacitor.
2. Remove the bolts and studs in the sequence shown.
   Fig 43: Removing Bolts & Studs

   Courtesy of FORD MOTOR CO.
3. Remove the intake manifold.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to clean the surfaces.
Fig 44: Removing Intake Manifold
Courtesy of FORD MOTOR CO.
4. Clean the sealing surfaces.

ITEMS 69-71: RH VALVE COVER REMOVAL NOTE 

1. Remove the bolts in the sequence shown and remove the RH valve cover.
   Fig 45: Removing RH Valve Cover

   Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to clean the surfaces.
Fig 46: Removing Gaskets & All Silicone Sealer
Courtesy of FORD MOTOR CO.
2. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.

ITEMS 73-75: LH VALVE COVER REMOVAL NOTE 

1. Remove the bolts in the sequence shown and remove the LH valve cover.
   Fig 47: Removing LH Valve Cover

   Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to clean the surfaces.
Fig 48: Removing Gaskets & All Silicone Sealer
Courtesy of FORD MOTOR CO.
2. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.

ITEM 86: RH EXHAUST MANIFOLD REMOVAL NOTE 

1. Remove the EGR tube.
   • Remove the nuts.
   • Remove the EGR tube.
   • Remove and discard the EGR tube gasket.
   Fig 49: Removing Discard EGR Tube Gasket

   Courtesy of FORD MOTOR CO.

ITEMS 89 AND 90: ENGINE FRONT COVER REMOVAL NOTE 

1. Remove the engine front cover.
   • Remove the bolts in the sequence shown.
   • Remove the engine front cover.
     Fig 50: Removing Engine Front Cover

     Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Fig 51: Cleaning Sealing Surfaces
Courtesy of FORD MOTOR CO.
2. Clean the sealing surfaces.

ITEMS 97-115, 112-122, 124: TIMING DRIVE COMPONENTS REMOVAL NOTE 

1. Remove the crankshaft position (CKP) sensor.
   Fig 52: Removing Crankshaft Position (CKP) Sensor

   Courtesy of FORD MOTOR CO.
NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.
2. Install the special tool.
   • Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
   • Install the special tool.
     Fig 53: Installing Special Tool

     Courtesy of FORD MOTOR CO.
3. Make sure the flats of the camshaft are facing upward. If not, repeat Step 1.
   Fig 54: Positioning Camshaft Flats Upward

   Courtesy of FORD MOTOR CO.
CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
Fig 55: Installing Special Tool On RH Cylinder Head
Courtesy of FORD MOTOR CO.
4. Install the special tool on the RH cylinder head.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
Fig 56: Removing Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
5. Remove and discard the exhaust camshaft sprocket bolt.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
Fig 57: Removing Discard Variable Camshaft Timing (VCT) Unit Bolt
Courtesy of FORD MOTOR CO.
6. Remove and discard the variable camshaft timing (VCT) unit bolt.
7. Remove the RH timing chain tensioner.
   1. Push the lever down and install a drill rod to lock the piston.
   2. Remove the bolts and the tensioner.
      Fig 58: Removing Bolts & Tensioner

      Courtesy of FORD MOTOR CO.
8. Remove the tensioner arm.
   Fig 59: Removing Tensioner Arm

   Courtesy of FORD MOTOR CO.
9. Remove the timing chain guide.
   Fig 60: Removing Timing Chain Guide

   Courtesy of FORD MOTOR CO.
10. Remove the RH primary timing chain.
    Fig 61: Removing RH Primary Timing Chain

    Courtesy of FORD MOTOR CO.
11. Remove the special tool from the RH head.
    Fig 62: Removing Special Tool From RH Head

    Courtesy of FORD MOTOR CO.
CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
Fig 63: Installing Special Tool On LH Head
Courtesy of FORD MOTOR CO.
12. Install the special tool on the LH head.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the cylinder head will occur.
Fig 64: Removing LH VCT Unit Bolt and Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
13. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
14. Remove the LH timing chain tensioner.
    1. Push the lever down and install a drill rod to lock the piston.
    2. Remove the bolts and the tensioner.
    Fig 65: Removing LH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
15. Remove the tensioner arm.
    Fig 66: Removing Tensioner Arm

    Courtesy of FORD MOTOR CO.
16. Remove the timing chain guide.
    Fig 67: Removing Timing Chain Guide

    Courtesy of FORD MOTOR CO.
17. Remove the LH primary timing chain.
    Fig 68: Removing LH Primary Timing Chain

    Courtesy of FORD MOTOR CO.
18. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 69: Installing A Pin To Lock Piston

    Courtesy of FORD MOTOR CO.
19. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 70: Removing LH VCT Unit Exhaust Camshaft Sprocket & Timing Chain

    Courtesy of FORD MOTOR CO.
20. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 71: Installing A Pin To Lock Piston

    Courtesy of FORD MOTOR CO.
21. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 72: Removing RH VCT Unit Exhaust Camshaft Sprocket & Timing Chain As An Assembly

    Courtesy of FORD MOTOR CO.
22. Remove the special tool from the LH head.
    Fig 73: Removing Special Tool From LH Head

    Courtesy of FORD MOTOR CO.

ITEMS 126-141: RH AND LH CAMSHAFT REMOVAL NOTE 

CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.
CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.
1. Record the camshaft component locations prior to removal.

ITEMS 142-147: RH AND LH CYLINDER HEAD REMOVAL NOTE 

CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTE: RH cylinder head shown, LH cylinder similar.
Fig 74: Removing & Discard Bolts
Courtesy of FORD MOTOR CO.
1. Remove and discard the bolts.
NOTE: RH cylinder head shown, LH cylinder similar.
Fig 75: Removing Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
2. Remove and discard the head bolts in the sequence shown.
NOTE: RH cylinder head shown, LH cylinder similar.
Fig 76: Removing & Discard Head Gasket(s)
Courtesy of FORD MOTOR CO.
3. Remove and discard the head gasket(s).
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
4. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
   1. Remove any large deposits of silicone or gasket material with a plastic scraper.
   2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
   3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
   4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
5. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).