Disconnect the battery ground cable.
WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components.
Relieve the fuel system pressure.
Remove engine air cleaner outlet tube.
Remove the timing belt.
Remove the vacuum hoses at the:
positive crankcase ventilation valve (PCV valve).
Fuel pressure sensor.
Disconnect the speed control cable and the accelerator cable from the control lever.
Disconnect the fuel charging wiring electrical connectors at main engine connector.
Disconnect the crankshaft position sensor (CKP sensor) electrical connector.
Disconnect the heated oxygen sensor H02S.
Disconnect the fuel line.
Remove the power steering pump and bracket as an assembly.
Remove the generator (GEN).
Remove the oil level indicator tube.
Raise the vehicle.
Drain the engine coolant.
Remove the splash shield bolts and remove the splash shield.
Disconnect the A/C compressor electrical connector.
Remove the A/C compressor.
Lower the vehicle.
Remove the spark plug wires and spark plugs.
Remove the valve cover.
Disconnect the upper radiator hose from the thermostat housing water hose connection.
Disconnect the heater water hose from the thermostat housing.
Remove the camshafts.
Remove the ignition coil and bracket.
Remove the water thermostat housing.
Remove the bolts and the cylinder head.
Remove the cylinder head gasket and discard.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
CAUTION: Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge the aluminum sealing surfaces.
Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness.
Install a new head gasket on the cylinder block.
CAUTION: Do not attempt to install the cylinder head assembly without assistance. Installation of the cylinder head assembly requires two people or possible injury may occur.
CAUTION: The bolts are torque-to-yield and must be replaced or engine damage may occur.
Tighten the bolts in three stages in sequence shown.
Stage 1: Tighten the bolts to 15 - 25 Nm (12 - 18 ft. Lbs.).
Stage 2: Tighten the bolts to 35 - 45 Nm (26 - 33 ft. Lbs.).
Stage 3: Tighten the bolts an additional 105 degrees.
Install the remaining components.
Drain engine Oil and replace the oil filter. Fill the crankcase with Super Premium 5W30 SAE Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2Cl58-G.
Fill the engine cooling system.
Charge the A/C system.
Run the engine and inspect for leaks.
Wednesday, August 29th, 2012 AT 7:53 PM