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Cylinder Head: Installation

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
  3. Inspect the cylinder head for distortion. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  4. Apply silicone gasket and sealant to the locations shown.
    Fig 1: Identifying Silicone Gasket And Sealant Location
    G03897827Courtesy of FORD MOTOR CO.
  5. Install a new head gasket.
    6. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    NOTE: Lubricate the bolts with clean engine oil prior to installation.
  6. Install 10 new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
    • Stage 1: Tighten to 7 Nm (62 lb-in).
    • Stage 2: Tighten to 15 Nm (11 lb-ft).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
      Fig 2: Identifying Tightening Sequence Cylinder Head Bolts
      G04680103Courtesy of FORD MOTOR CO.

    7. Vehicles with secondary air injection (AIR) 

  7. Position AIR valve bracket and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

    8. All vehicles 

  8. Connect the coolant hose to the EGR valve.
  9. Connect the EGR valve electrical connector.
  10. Connect the ECT electrical connector.
  11. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
    Fig 3: Locating Retaining Clip
    G04680104Courtesy of FORD MOTOR CO.
  12. Attach the EVAP tube bundle retaining clip retaining clip.
    13. NOTE: Coat the valve tappets with clean engine oil prior to installation.
  13. Install the valve tappets.
    14. CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  14. Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3 stages:
    • Stages 1: Tighten the camshaft bearing cap bolts until finger tight.
    • Stages 2: Tighten to 7 Nm (62 lb-in).
    • Stages 3: Tighten to 16 Nm (12 lb-ft).
      Fig 4: Identifying Tightening Sequence Of Camshaft Bearing Caps
      G04680105Courtesy of FORD MOTOR CO.
  15. Install the special tool.
    Fig 5: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  16. Install the VCT solenoid and bolt.
    • Tighten to 10 Nm (89 lb-in).
  17. Install the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS .
  18. Install the engine mount bracket and the 2 nuts.
    • Tighten to 103 Nm (76 lb-ft).
  19. Using the special too, lift the engine 25 mm (0.98 in).
    Fig 6: Identifying Special Tool
    G04680107Courtesy of FORD MOTOR CO.
  20. Install the engine mount, nut and 2 bolts.
    • Tighten to 55 Nm (41 lb-ft).
  21. Lower the engine 25 mm (0.98 in).
  22. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
  23. Install the radio frequency interference capacitor and bolt to the engine mount bracket.
    • Tighten to 10 Nm (89 lb-in).

    24. Vehicles with secondary air injection (AIR) 

  24. Install the AIR pump and the 3 bolts.
    • Tighten to 30 Nm (22 lb-ft).
  25. Connect the AIR pump electrical connector.

    26. All vehicles 

  26. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  27. Install the fuel supply rail. For additional information, refer to FUEL CHARGING & CONTROLS - 2.3L .
  28. Install the generator. For additional information, refer to GENERATOR AND REGULATOR .
  29. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  30. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  31. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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