Ford Freestar, Monterey 2004-2006

Cylinder Head

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Removal & Installation



Left Side
  1. Relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Pushrods must be installed in their original positions. Note pushrod location during removal.



    Negative battery cable
     
    Coolant
     
    Dual converter Y-pipe.
     
    Exhaust manifold
     
    Upper and lower intake manifolds
     
    Alternator and mounting bracket
     
    A/C compressor and mounting bracket
     
    Valve covers
     



    Pushrods
     
    Rotate tensioner clockwise and remove accessory drive belt
     
    Automatic belt tensioner assembly
     
    Lower exhaust manifold mounting studs
     
    Spark plugs
     
    Cylinder head bolts
     
    Cylinder head from the engine block and discard the gaskets
     

  4.  

To install:

  1. The cylinder head should be cleaned and inspected prior to installation.
  2.  
  3. Lightly oil all bolt and stud bolt threads before installation.
  4.  
  5. Clean all gasket mating surfaces thoroughly.
  6.  
  7. Install or connect the following:
    WARNING
    Always use new cylinder head bolts when installing the cylinder head or damage to the engine may occur.


    NOTE
    Long bolts go in the inside of the cylinder head and short bolts go on the outside.


    NOTE
    The rocker arm seats must be fully seated in the cylinder head and the pushrods must be seated in the rocker arm sockets prior to the final tightening.



    New head gaskets on the cylinder block.
     



    Cylinder head on the cylinder block.
     



    Tighten the cylinder head bolts in steps following the proper torque sequence. The first step is 14 ft. lbs. (20 Nm), the second step is 29 ft. lbs. (40 Nm), the third step is 36 ft. lbs. (50 Nm).
     
    Using the torque sequence, loosen the first long bolt 3 turns, then tighten the bolt to 30 ft. lbs. (40 Nm). Tighten the bolt an additional 180 degrees. Using the torque sequence, loosen the first short bolt 3 turns, then tighten the bolt to 18 ft. lbs. (25 Nm). Tighten the bolt an additional 180 degrees. Repeat these steps for each bolt in sequence using the proper torque for long and short bolts.

    Click image to see an enlarged view

    Fig. Left side cylinder head bolt torque sequence-3.9L and 4.2L engines

     
    Lower exhaust manifold mounting studs
     
    Pushrods. Dip each end in engine assembly lubricant.
     
    Rocker arms, seats and retaining bolts. Lubricate all rocker arm components with engine assembly lubricant. Tighten the bolts to 44 inch lbs. (5 Nm).
     



    Final tighten all rocker arm retaining bolts to 24 ft. lbs. (32 Nm)
     
    Automatic belt tensioner assembly
     
    Accessory drive belt
     
    Valve covers
     
    A/C compressor and mounting bracket
     
    Alternator and mounting bracket
     
    Upper and lower intake manifolds
     
    Exhaust manifold
     
    Dual converter Y-pipe.
     

  8.  
  9. Fill and bleed the cooling system.
    NOTE
    Engine coolant is corrosive to engine bearing material. Replace the engine oil after removal of any coolant-carrying component to help prevent potential bearing damage.

  10.  
  11. Change the engine oil and filter
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and check for leaks.
  16.  

Right Side
  1. Remove or disconnect the following:
    NOTE
    Pushrods must be installed in their original positions. Note pushrod location during removal.



    Negative battery cable
     
    Coolant
     
    Dual converter Y-pipe.
     
    Exhaust manifold
     
    Upper and lower intake manifolds
     
    Power steering pump and mounting bracket
     
    Valve covers
     



    Pushrods
     
    Rotate tensioner clockwise and remove accessory drive belt
     
    Automatic belt tensioner assembly
     
    Lower exhaust manifold mounting studs
     
    Spark plugs
     
    Cylinder head bolts
     
    Cylinder head from the engine block and discard the gaskets

    Click image to see an enlarged view

    Fig. Right side cylinder head bolt torque sequence-3.9L and 4.2L engines

     

  2.  

To install:

  1. The cylinder head should be cleaned and inspected prior to installation.
  2.  
  3. Lightly oil all bolt and stud bolt threads before installation.
  4.  
  5. Clean all gasket mating surfaces thoroughly.
  6.  
  7. Install or connect the following:
    WARNING
    Always use new cylinder head bolts when installing the cylinder head or damage to the engine may occur.


    NOTE
    Long bolts go in the inside of the cylinder head and short bolts go on the outside.


    NOTE
    The rocker arm seats must be fully seated in the cylinder head and the pushrods must be seated in the rocker arm sockets prior to the final tightening.



    New head gaskets on the cylinder block.
     



    Cylinder head on the cylinder block.
     



    Tighten the cylinder head bolts in steps following the proper torque sequence. The first step is 14 ft. lbs. (20 Nm), the second step is 29 ft. lbs. (40 Nm), the third step is 36 ft. lbs. (50 Nm).
     
    Using the torque sequence, loosen the first long bolt 3 turns, then tighten the bolt to 30 ft. lbs. (40 Nm). Tighten the bolt an additional 180 degrees. Using the torque sequence, loosen the first short bolt 3 turns, then tighten the bolt to 18 ft. lbs. (25 Nm). Tighten the bolt an additional 180 degrees. Repeat these steps for each bolt in sequence using the proper torque for long and short bolts.
     
    Lower exhaust manifold mounting studs
     
    Pushrods. Dip each end in engine assembly lubricant.
     
    Rocker arms, seats and retaining bolts. Lubricate all rocker arm components with engine assembly lubricant. Tighten the bolts to 44 inch lbs. (5 Nm).
     



    Final tighten all rocker arm retaining bolts to 24 ft. lbs. (32 Nm)
     
    Automatic belt tensioner assembly
     
    Accessory drive belt
     
    Valve covers
     
    Power steering pump and mounting bracket
     
    Upper and lower intake manifolds
     
    Exhaust manifold
     
    Dual converter Y-pipe.
     

  8.  
  9. Fill and bleed the cooling system.
    NOTE
    Engine coolant is corrosive to engine bearing material. Replace the engine oil after removal of any coolant-carrying component to help prevent potential bearing damage.

  10.  
  11. Change the engine oil and filter
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and check for leaks.
  16.  

 
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