Disassembly and Assembly of Sub-Assemblies - Cylinder Head

Special Service Tools / General Equipment

	303-300 (T87C-6565-A) Kit, Valve Spring Compressor TKIT-1988-FESTIVA T88C-1000-ST TKIT-1988-TRACER TKIT-2009TC-F
	303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1990-LMX TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM
	303-468 (T94P-6510-AX) Remover, Valve Stem Seal TKIT-1994-LMH/MH2 TKIT-1994-FX/FMX/FLMX
	303-470 (T94P-6510-C) Installer, Valve Stem Seal TKIT-1994-LMH/MH2 TKIT-2009TC-F TKIT-1994-FX/FMX/FLMX
	303-472 (T94P-6565-AX) Adapter, Valve Spring Compressor TKIT-1994-LMH/MH2 TKIT-1994-FX/FMX/FLMX
	307-005 (T59L-100-B) Slide Hammer

Materials

DISASSEMBLY

1. 1
   Remove the bolts and the fuel rail.

   

2. 2
   Remove the bolts and the fuel rail.

   

3. 3
   Remove and discard the fuel injector O-rings and the fuel injector clips.

   

4. 4
   Remove the bolt and the lifting bracket.

   

5. 5
   Remove the plug.

   

6. 6
   Remove and discard the plug gasket.

   

7. 7
   Remove the bolts and the water outlet housing.

   

8. 8
   Remove and discard the water outlet housing gasket.

   

9. 9
   Remove and discard the CHT sensor.

   

10. 10
    Remove the spark plugs.

    

11. 11
    Using the special tools, remove the valve keepers, valve spring retainers and valve springs.
    Use the Special Service Tool: 303-300 (T87C-6565-A) Kit, Valve Spring Compressor, 303-350 (T89P-6565-A) Compressor, Valve Spring, 303-472 (T94P-6565-AX) Adapter, Valve Spring Compressor.
    Material: Motorcraft® Multi-Purpose Spray Lubricant / XL-5-A (ESB-M1C93-B)

    

12. 12
    Inspect and install new components as necessary.

    

13. 13
    Using the special tools, remove and discard the valve stem seals.
    Use the Special Service Tool: 303-468 (T94P-6510-AX) Remover, Valve Stem Seal, 307-005 (T59L-100-B) Slide Hammer.

    

14. 14
    Remove the valves.

    

15. 15
    Inspect the following valve areas:
    

    1. Valve stem end for grooves or scoring.

    2. Valve face and margin for pits, grooves or scratches.

    3. Valve head for signs of burning, erosion, warping and cracking.

    4. Valve margin for wear.

    

ASSEMBLY

1. 1
   Refer to: Specifications (Engine 303-01C, Specifications).

   

2. 2
   Lubricate with clean engine oil and, using the special tool, install the valve stem seal.
   Refer to: Specifications (Engine 303-01C, Specifications).
   Use the Special Service Tool: 303-470 (T94P-6510-C) Installer, Valve Stem Seal.

   

3. 3
   Using the special service tools, install the valve springs, valve spring retainers and valve keepers (collets).
   Special Service Tools: 303-300 (T87C-6565-A) Kit, Valve Spring Compressor. , 303-350 (T89P-6565-A) Compressor, Valve Spring. , 303-472 (T94P-6565-AX) Adapter, Valve Spring Compressor.
   Material: Motorcraft® Universal Lubricant Spray / XL-5-A (ESB-M1C93-B)

   

4. 4
   Install the spark plugs.
   Torque: 106 lb-in (12 N·m)

   

5. 5
   Install the new CHT sensor.
   Torque: 106 lb-in (12 N·m)

   

6. 6
   Install a new water outlet housing gasket.

   

7. 7
   Install the water outlet housing and hand-tighten the bolts.
   

   • Tighten in the sequence shown.
     Torque:
     Stage 1: 89 lb-in (10 N·m)
     Stage 2: 45°

   

8. 8
   Install a new plug gasket.

   

9. 9
   Install the plug and bolts.
   Torque: 177 lb-in (20 N·m)

   

10. 10
    Install the lifting bracket and bolt.
    Torque: 39 lb-ft (53 N·m)

    

11. 11

    NOTICE: Use O-rings made of special fuel-resistant material. Using standard O-rings may cause the system to leak. Do not reuse O-rings.

    Install new fuel injector O-rings and fuel injector clips. Lubricate the new O-rings with clean engine oil.
    Refer to: Specifications (303-01C Engine, Specifications).

    

12. 12
    Install the fuel injectors into the fuel rail.

    

13. 13
    Install the fuel rail assembly and studs.
    Torque:
    Stage 1: 18 lb-ft (25 N·m)
    Stage 2: 30°