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Cylinder Head: Disassembly

NOTE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

LH cylinder head 

    • Remove the nuts and the exhaust manifold.

    • Discard the nuts.

    GFD859558Courtesy of FORD MOTOR COMPANY
    • Remove the discard the exhaust manifold gasket.

    • Remove and discard the studs.

    GFD859559Courtesy of FORD MOTOR COMPANY

    • NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

      Clean the exhaust manifold mating surface of the cylinder head with metal surface prep wipes. Follow the directions on the packaging.

      Material: Primer

    GFD859155Courtesy of FORD MOTOR COMPANY
    1. Remove and discard the direct injection fuel rail mounting bolts.
    2. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
      NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

      Remove the direct injection fuel rail and the fuel injectors.

    GFD859560Courtesy of FORD MOTOR COMPANY
  5. Disconnect the fuel injector electrical connectors.
    GFD859446Courtesy of FORD MOTOR COMPANY
    • Release the fuel injector retaining clips.

    • Remove the fuel injectors from the fuel rail.

    GFD859447Courtesy of FORD MOTOR COMPANY
  7. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.
    GFD859448Courtesy of FORD MOTOR COMPANY
    • Remove and discard the fuel injector O-ring seals.

    • NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.

      Remove and discard the fuel injector support rings.

    GFD859449Courtesy of FORD MOTOR COMPANY
  9. NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
    NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.

    • Pull the lower Teflon® seal away from the injector.

    • Carefully cut and discard the lower fuel injector Teflon® seals.

    GFD859450Courtesy of FORD MOTOR COMPANY

    RH cylinder head 

  10. Remove the EGR to exhaust manifold connector.
    GFD859561Courtesy of FORD MOTOR COMPANY
    • Remove the nuts and the exhaust manifold.

    • Discard the nuts.

    GFD859562Courtesy of FORD MOTOR COMPANY
  12. Remove and discard the studs and the exhaust manifold gasket.
    GFD859563Courtesy of FORD MOTOR COMPANY

    • NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

      Clean the exhaust manifold mating surface of the cylinder head with metal surface prep wipes. Follow the directions on the packaging.

      Material: Primer

    GFD859162Courtesy of FORD MOTOR COMPANY
    1. Remove and discard the direct injection fuel rail mounting bolts.
    2. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
      NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

      Remove the direct injection fuel rail and the fuel injectors.

    GFD859564Courtesy of FORD MOTOR COMPANY
  15. Disconnect the fuel injector electrical connectors.
    GFD859454Courtesy of FORD MOTOR COMPANY
    • Release the fuel injector retaining clips.

    • Remove the fuel injectors from the fuel rail.

    GFD859455Courtesy of FORD MOTOR COMPANY
  17. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.
    GFD859448Courtesy of FORD MOTOR COMPANY
    • Remove and discard the fuel injector O-ring seals.

    • NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.

      Remove and discard the fuel injector support rings.

    GFD859449Courtesy of FORD MOTOR COMPANY
  19. NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
    NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.

    • Pull the lower Teflon® seal away from the injector.

    • Carefully cut and discard the lower fuel injector Teflon® seals.

    GFD859450Courtesy of FORD MOTOR COMPANY

    All cylinder heads 

  20. NOTE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur.

    Using the special tools, remove the fuel injectors that remained in the cylinder head.Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector.

    GFD859565Courtesy of FORD MOTOR COMPANY
  21. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
    NOTE: Do not use compressed air to clean the tip of the fuel injector.
    NOTE: Do not use a brush to clean the tip of the fuel injector.

    Using the special tool, clean the cylinder head fuel injector bores.Use Special Service Tool: 310-205 Fuel Injector Brush.

    GFD859566Courtesy of FORD MOTOR COMPANY
  22. Remove the spark plugs.
    GFD859567Courtesy of FORD MOTOR COMPANY
  23. NOTE: LH shown below, RH similar.
    NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

    Using the special tools, remove the valve collet, valve spring retainer and the valve spring.Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor., 303-350 (T89P-6565-A) Compressor, Valve Spring., 303-1249 Valve Spring Compressor., 303-1418 Compressor, Valve Spring.

    GFD859568Courtesy of FORD MOTOR COMPANY
  24. Remove and discard the valve stem seal.
    GFD859569Courtesy of FORD MOTOR COMPANY
  25. Remove the valve.
    GFD859570Courtesy of FORD MOTOR COMPANY
  26. Repeat the previous 3 steps for each valve.
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