Ford AT4Z-6049-B Cylinder Head Assembly

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To remove the components, first relieve the fuel pressure, then disconnect the cable from the negative battery terminal. Next, remove the air filter housing along with the charger air cooler inlet and outlet pipes, followed by the power steering pump and bracket if equipped, and the alternator. Drain the cooling system and remove the turbocharger, coolant expansion tank, and timing chain, ensuring to check valve clearances before disassembly if camshafts are removed. Disconnect the Camshaft Position sensor electrical connector, unbolt and remove the VCT solenoid valves from the front camshaft bearing cap, and take out the camshafts and lifters while keeping the lifters in order. Remove the fuel rail and injectors, disconnect hoses from the coolant outlet housing, and take off the intake manifold. For 2019 models, disconnect electrical connectors from the EGR valve and remove the EGR valve, transducer, bracket, and tube. If an engine support fixture interferes with the cylinder head removal, use a floor jack for support. Loosen the cylinder head bolts progressively, then lift the cylinder head from the engine compartment, taking care not to damage it. Once removed, discard the gasket and check for locating dowels. Clean the mating faces of the cylinder head and block thoroughly, ensuring no carbon enters oil and water passages, and check for damage on the surfaces. Wipe clean the mating surfaces and install alignment dowels if equipped. Position a new gasket on the cylinder block surface with the "TOP" mark facing up, and use guide studs to assist in installing the heavy cylinder head. Coat the threads of the new cylinder head bolts with engine oil, install them until finger-tight, and then tighten them progressively in the specified sequence. Finally, reverse the removal process for other components, change the engine oil and filter, and refill the cooling system.

To remove the components, first relieve the fuel pressure, then disconnect the cable from the negative battery terminal. Next, remove the air filter housing along with the charger air cooler inlet and outlet pipes, followed by the power steering pump and bracket if equipped, and the alternator. Drain the cooling system and remove the turbocharger, coolant expansion tank, and timing chain, ensuring to check valve clearances before disassembly if camshafts are removed. Disconnect the Camshaft Position sensor electrical connector, unbolt and remove the VCT solenoid valves from the front camshaft bearing cap, and take out the camshafts and lifters while keeping the lifters in order. Remove the fuel rail and injectors, disconnect hoses from the coolant outlet housing, and take off the intake manifold. For 2019 models, disconnect electrical connectors from the EGR valve and remove the EGR valve, transducer, bracket, and tube. If an engine support fixture interferes with the cylinder head removal, use a floor jack for support. Loosen the cylinder head bolts progressively, then lift the cylinder head from the engine compartment, taking care not to damage it. Once removed, discard the gasket and check for locating dowels. Clean the mating faces of the cylinder head and block thoroughly, ensuring no carbon enters oil and water passages, and check for damage on the surfaces. Wipe clean the mating surfaces and install alignment dowels if equipped. Position a new gasket on the cylinder block surface with the "TOP" mark facing up, and use guide studs to assist in installing the heavy cylinder head. Coat the threads of the new cylinder head bolts with engine oil, install them until finger-tight, and then tighten them progressively in the specified sequence. Finally, reverse the removal process for other components, change the engine oil and filter, and refill the cooling system.

New cylinder head bolts must be used for reassembly. Failure to use new bolts may result in cylinder head gasket leakage and engine damage. 15. The mating surfaces of the cylinder heads and engine block must be perfectly clean when the cylinder heads are installed. Use a gasket scraper to remove all traces of carbon and old gasket material, then clean the mating surfaces with lacquer thinner or acetone. If there's oil on the mating surfaces when the cylinder heads are installed, the gaskets may not seal correctly and leaks may develop. Cover the open areas of the engine with shop rags to keep debris out during repair and reassembly. Use a vacuum cleaner to remove any debris that falls into the cylinders. Do not use abrasive wheels or sharp metal scrapers on the heads or block surface; use a plastic scraper and chemical gasket remover, or the head gasket surfaces could develop leaks. 16. Check the engine block and cylinder head mating surfaces for nicks, deep scratches, and other damage. 17. Use a tap of the correct size to chase the threads in the cylinder head bolt holes. Dirt, corrosion, sealant, and damaged threads will affect torque readings. 18. Make sure the new gaskets are installed on the correct cylinder banks (Identify the left and right cylinder head gaskets; the shapes are different and cannot be interchanged). 19. Position the new gasket(s) over the alignment dowels in the engine block. 20. Carefully position the cylinder heads on the engine block without disturbing the gaskets. Install the NEW cylinder head bolts (the cylinder head bolts are torque-to-yield design and they cannot be reused). Following the recommended sequence, tighten the cylinder head bolts in five steps, to the torque and angle of rotation. Note: The method used for the cylinder head bolt tightening procedure is referred to as "torque-angle" or "torque-to-yield" method. Follow the procedure exactly. Tighten the bolts in the first step using a torque wrench, then use a breaker bar and a special torque-angle gauge to tighten the bolts the required angle. If the adapter is not available, mark each bolt with a paint stripe to aid in the torque angle process. 21. The remaining installation steps are the reverse of removal. 22. Install the engine. 23. Change the engine oil and filter and refill the cooling system, then start the engine and check carefully for oil and coolant leaks.

Cylinder head disassembly and inspection procedures should be performed by a qualified automotive machine shop.

Note: This procedure can only be done with the engine removed.

Store the cylinder heads on wood blocks to prevent damage to the gasket sealing surfaces.

The mating surfaces must be perfectly clean when the cylinder heads are installed.

If resistance is felt, place a wood block against the end of the cylinder head and strike the wood block with a hammer.

Disconnect any electrical connectors from the cylinder head and mark them with tape for correct reassembly.