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Cylinder Head: Disassembly

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.
NOTE: This procedure is considered a major service repair. For Ford warranty coverage, the vehicle must be returned to the Multimatic vehicle assembly and repair facility.

LH cylinder head 

  1. Remove Special Service Tool: 303-1654 Lift Eyes.
    GFD344862Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the bottom exhaust manifold heat shield.

    • Discard the bolts.

    GFD344863Courtesy of FORD MOTOR COMPANY
    • Remove the nuts and the exhaust manifold.

    • Discard the nuts.

    GFD344864Courtesy of FORD MOTOR COMPANY
    • Remove the discard the exhaust manifold gasket.

    • Remove and discard the studs.

    GFD344865Courtesy of FORD MOTOR COMPANY
  5. Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .
    1. Remove and discard the port 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.

      Remove the port injection fuel rail and the fuel injectors.

    GFD344866Courtesy of FORD MOTOR COMPANY
  7. Disconnect the fuel injector electrical connectors.
    GFD344867Courtesy of FORD MOTOR COMPANY
    • Release the fuel injector retaining clips.

    • Remove the fuel injectors from the fuel rail.

    GFD344868Courtesy of FORD MOTOR COMPANY
  9. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.
    GFD344869Courtesy of FORD MOTOR COMPANY
  10. Remove and discard all of the fuel injector O-ring seals.
    GFD344870Courtesy 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.

    GFD344871Courtesy of FORD MOTOR COMPANY
  12. Disconnect the fuel injector electrical connectors.
    GFD344872Courtesy of FORD MOTOR COMPANY
    • Release the fuel injector retaining clips.

    • Remove the fuel injectors from the fuel rail.

    GFD344873Courtesy of FORD MOTOR COMPANY
  14. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.
    GFD344874Courtesy 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.

    GFD344875Courtesy of FORD MOTOR COMPANY
  16. 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.

    GFD344876Courtesy of FORD MOTOR COMPANY

    RH cylinder head 

  17. Remove Special Service Tool: 303-1654 Lift Eyes.
    GFD344877Courtesy of FORD MOTOR COMPANY
  18. Remove and discard the CHT sensor.
    GFD344878Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the bottom exhaust manifold heat shield.

    • Discard the bolts.

    GFD344879Courtesy of FORD MOTOR COMPANY
    • Remove the nuts and the exhaust manifold.

    • Discard the nuts.

    GFD344880Courtesy of FORD MOTOR COMPANY
  21. Remove and discard the studs and the exhaust manifold gasket.
    GFD344881Courtesy of FORD MOTOR COMPANY
  22. Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .
    1. Remove and discard the port 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.

      Remove the port injection fuel rail and the fuel injectors.

    GFD344882Courtesy of FORD MOTOR COMPANY
  24. Disconnect the fuel injector electrical connectors.
    GFD344883Courtesy of FORD MOTOR COMPANY
    • Release the fuel injector retaining clips.

    • Remove the fuel injectors from the fuel rail.

    GFD344884Courtesy of FORD MOTOR COMPANY
  26. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.
    GFD344869Courtesy of FORD MOTOR COMPANY
  27. Remove and discard all of the fuel injector O-ring seals.
    GFD344870Courtesy 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.

    GFD344885Courtesy of FORD MOTOR COMPANY
  29. Disconnect the fuel injector electrical connectors.
    GFD344886Courtesy of FORD MOTOR COMPANY
    • Release the fuel injector retaining clips.

    • Remove the fuel injectors from the fuel rail.

    GFD344887Courtesy of FORD MOTOR COMPANY
  31. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.
    GFD344874Courtesy 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.

    GFD344875Courtesy of FORD MOTOR COMPANY
  33. 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.

    GFD344876Courtesy of FORD MOTOR COMPANY

    All cylinder heads 

  34. 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.

    GFD344888Courtesy of FORD MOTOR COMPANY
  35. 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.

    GFD344889Courtesy of FORD MOTOR COMPANY
  36. Remove the spark plugs.
    GFD344890Courtesy of FORD MOTOR COMPANY
  37. NOTE: LH shown, 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: 303-1418 Compressor, Valve Spring, 303-300 (T87C-6565-A) Set, Valve Spring Compressor, 303-350 (T89P-6565-A) Compressor, Valve Spring, 303-1249 Valve Spring Compressor.

    GFD344891Courtesy of FORD MOTOR COMPANY
  38. Remove and discard the valve stem seal.
    GFD344892Courtesy of FORD MOTOR COMPANY
  39. Remove the valve.
    GFD344893Courtesy of FORD MOTOR COMPANY
  40. Repeat the previous 3 steps for each valve.
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