Automotive Manual PDF

Valve Removal Instructions
1. Place the Assembly Stand on the work surface and set the deck surface of the cylinder head on the protective foam. The Assembly Stand will prevent the head from moving during disassembly
2. Valve Support Selection: Choose the appropriate valve support component. A Shot-Bag or Chamber Plug must be used to hold up the valves while removing the valve locks.
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Installing spark plugs
Torque is one of the most critical aspects of spark plug installation. Torque directly affects the spark plugs’ ability to transfer heat out of the combustion chamber. A spark plug that is under-torqued will not be fully seated on the cylinder head, hence heat transfer will be slowed. This will tend to elevate combustion chamber temperatures to unsafe levels, and pre-ignition and detonation will usually follow. Serious engine damage is not far behind.
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If you only ordered the pair of covers for the two diagonal spots with “holes” (the Left Front and the Right Rear plugs), you will not have the M6 Phillips head screws in your package, nor the large allen wrench. If you only ordered the two diagonal covers for the spots without “holes” (the Left Rear and the Right Front plugs), then you will not have the brackets, the 1 ū” screws, the ―” set screws, nor the small allen wrench.
Tools you will need to provide:
- medium Phillips head screw driver
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Full-Torque® thread repair inserts are made of hard anodized aluminum for spark plug holes in aluminum cylinder heads and steel, for cast iron heads. FFT-Style Deep Reach inserts match the Ford Triton 4.6, 5.4 and 6.8 liter engines. Inserts for aluminum heads are made of hard anodized aluminum for optimum heat transfer.
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Instructions for installing spark plug thread repair insert in the Ford Triton 2 valve 2000 to 2003 heads
Full Thread style inserts should be used when both heads have been removed from the engine and all 8 cylinders are upgraded to prevent future failures.

Deep Reach style inserts should be used when only installing one insert during an in-frame installation. This will assure that all spark plug holes are the same and installation of the wrong spark plug can’t happen to an unsuspecting future owner of the vehicle.
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THEORY OF 6 SERIES IGNITION
CAPACITIVE DISCHARGE
The MSD 6 Series Ignitions feature a capacitive discharge ignition design. The majority of stock ignition systems are inductive ignitions. In an inductive ignition, the coil must store and step up the voltage to maximum strength in between each firing. At higher rpm, since there is less time to charge the coil to full capacity, the voltage falls short of reaching maximum energy which results in a loss of power or top end miss. The MSD Ignition features a capacitor which is quickly charged (within one millisecond) with 460 - 480 volts and stores it until the ignition is triggered. With the CD design, the voltage sent to the coil is always at full power even at high rpm.
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The Ford Triton Spark plug holes have been divided into three Types formodel years 1993 through 2005. The drawings below will help you identify each Type. Each individual cylinder head will have the same Type for all spark plug holes.

Gauge FT5CG will help you identify which Type the head is so you can make sure to use the correct installation tooling and can verify if the insert was installed to the same depth as original. Complete information on the use of this tool and installation of the inserts are contained in these instructions.
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This system is intended for installation on vehicles equipped with automatic transmissions and electronic fuel injection only!
• This product must be installed by qualified personnel according to these instructions and and observing all safety features.
• The system should be placed into the valet mode when parked inside a garage or being left for service.
• Always notify service personnel that the vehicle is equipped with a Remote Starter.
• Only start the vehicle in a well ventilated area. Do not use in a closed garage or indoors
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Power Plant
Removing the cylinder head
Caution : The manufacturer assumes no responsibility for damage resulting from the use of unsuitable tools for the removal and refitting of the engine or any part of it.
When the engine is in place, the cylinder head, the cylinder, the piston and the reed valve can be exposed by removing the following parts: exhaust pipe, air filter casing, carburettor.
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Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay.
VALVE CLEARANCE
NOTE: Adjust valve clearance with engine cold.
NOTE: If valve cover uses grommets below retaining nuts or bolts, keep grommets in order so they are installed in original locations during reassembly.
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