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Cylinder Head: Installation

    All engines 

    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 new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages.
    • Stage 1: Tighten to 5 Nm (44 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 Cylinder Head Bolts Tightening Sequence
      G04652063Courtesy of FORD MOTOR CO.
  7. Install the EGR coolant hose.
  8. Using a new gasket, install the coolant bypass and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
  9. Connect the coolant hoses onto the coolant bypass.
  10. Connect the EGR valve electrical connector.
  11. Clean and inspect the catalytic converter flange.
    • Using a straightedge and a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
      Fig 3: Inspecting Catalytic Converter Flange W/Specs.
      G04652064Courtesy of FORD MOTOR CO.
  12. Using a new gasket and 7 nuts, install the catalytic converter.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 4: Locating Catalytic Converter Nuts Tightening Sequence
      G04652065Courtesy of FORD MOTOR CO.
  13. Connect the exhaust sensor electrical connectors.
    Fig 5: Locating Exhaust Sensor Electrical Connectors
    G04652066Courtesy of FORD MOTOR CO.
    14. NOTE: All 2.3L engines and some 2.0L engines are equipped with a heat shield that must be positioned aside to access the catalytic converter-to engine nuts.
  14. If equipped, position the heat shield and install the 4 heat shield bolts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 6: Locating Heat Shield Bolts
      G04652067Courtesy of FORD MOTOR CO.
  15. Install the catalytic converter support bracket and the 2 bolts to the engine.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 7: Locating Catalytic Converter Support Bracket And Bolts
      G04652068Courtesy of FORD MOTOR CO.

    16. 2.0L engines 

  16. If equipped, connect the upper exhaust sensor electrical connector and retainer.
    Fig 8: Locating Upper Exhaust Sensor Electrical Connector And Retainer
    G04652069Courtesy of FORD MOTOR CO.
  17. If equipped, connect the hoses to the AIR control valve.
    Fig 9: Locating Air Control Valve Hoses
    G04652070Courtesy of FORD MOTOR CO.
  18. If equipped, connect the AIR vacuum regulator electrical connector and vacuum hose.
    Fig 10: Locating Air Vacuum Regulator Electrical Connector And Vacuum Hose
    G04652071Courtesy of FORD MOTOR CO.

    19. All engines 

    NOTE: Lubricate the valve tappets with clean engine oil.
    Fig 11: Locating Valve Tappet
    G04652072Courtesy of FORD MOTOR CO.
  19. Install the valve tappets in their original positions.
    20. CAUTION: Install the camshafts with the alignment notches in the camshafts lined up so the camshaft alignment plate can be installed. Make sure the lobes on the No. 1 cylinder are in the same position at noted in the removal procedure. Failure to follow this procedure can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  20. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until the cam is fully seated.
    • Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
    • Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
      Fig 12: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
      G03897808Courtesy of FORD MOTOR CO.
  21. Install the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS  in this article.
  22. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD  in this article.
  23. Install the fuel injector supply manifold. For additional information, refer to FUEL CHARGING AND CONTROLS - 2.0L AND 2.3L .
  24. Install the generator. For additional information, refer to GENERATOR AND REGULATOR .
  25. Connect the radio interference capacitor electrical connector.
  26. Install the dual cooling fans and connect the electrical connectors.
  27. Install the battery tray. For additional information, refer to BATTERY MOUNTING AND CABLES .
  28. Drain the engine oil and change the filter.
    • Tighten the plug to 28 Nm (21 lb-ft).
  29. Fill the engine with clean engine oil.
  30. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  31. Fill the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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