Cylinder Head: Installation

Both cylinder heads 

NOTE: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Head .
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
NOTE: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.
NOTE: RH head gasket shown, LH head gasket similar.
1. Install the new head gasket over the dowel pins.
Fig 1: Head Gasket & Dowel Pins
Courtesy of FORD MOTOR CO.
NOTE: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.
NOTE: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Head .
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
NOTE: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.
NOTE: RH cylinder head shown, LH cylinder head similar.
2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
Fig 2: Locating Cylinder Head
Courtesy of FORD MOTOR CO.
3. Tighten the cylinder head bolts in 6 stages, in the sequence shown.
   • Stage 1: Tighten to 40 Nm (30 lb-ft).
   • Stage 2: Tighten an additional 90 degrees (1/4 turn).
   • Stage 3: Loosen a minimum of one full turn (360 degrees).
   • Stage 4: Tighten to 40 Nm (30 lb-ft).
   • Stage 5: Tighten an additional 90 degrees (1/4 turn).
   • Stage 6: Tighten an additional 90 degrees (1/4 turn).
Fig 3: Cylinder Head Bolt Torque Sequence
Courtesy of FORD MOTOR CO.
4. Remove the special tools from both ends of the cylinder head.
Fig 4: Identifying Special Tool (303-572)
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
5. Install the hydraulic lash adjusters in their original locations.
Fig 5: Locating Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.

LH cylinder head 

NOTE: Lubricate the O-ring seal with clean engine oil.
6. Install a new O-ring seal on the oil level indicator tube and install the oil level indicator tube and bolt.
   • Tighten to 10 Nm (89 lb-in).
Fig 6: Oil Level Indicator Tube Bolt
Courtesy of FORD MOTOR CO.
7. Install the 8 new LH exhaust manifold studs.
   • Tighten to 12 Nm (9 lb-ft).
8. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 new nuts.
   • Tighten to 25 Nm (18 lb-ft) in the sequence shown.
Fig 7: Exhaust Manifold Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.

RH cylinder head 

9. Install the 8 new RH exhaust manifold studs.
   • Tighten to 12 Nm (9 lb-ft).
10. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 new nuts.
    • Tighten to 25 Nm (18 lb-ft) in the sequence shown.
Fig 8: Exhaust Manifold Nuts Tightening Sequence
Courtesy of FORD MOTOR CO.

Engines with ratcheting timing chain tensioners 

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
NOTE: LH shown, RH similar.
11. Compress each tensioner plunger, using an edge of a vise.
Fig 9: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
12. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
Fig 10: Pushing Back And Holding Ratchet Mechanism
Courtesy of FORD MOTOR CO.
13. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Fig 11: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
14. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
    • Remove the tensioner from the vise.
Fig 12: Installing Paper Clip Into Tensioner Housing
Courtesy of FORD MOTOR CO.

Engines with non-ratcheting timing chain tensioners 

NOTE: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body or permanent compression of the seal bead, will require the installation of a new tensioner.
15. Inspect the RH and LH timing chain tensioners.
    • Install new tensioners as necessary.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTE: LH shown, RH similar.
16. Compress each tensioner plunger, using an edge of a vise.
Fig 13: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
17. Install a retaining clip on the tensioner to hold the plunger in during installation.
Fig 14: Identifying Retaining Clip on Tensioner
Courtesy of FORD MOTOR CO.

Both cylinder heads 

18. If the colored links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
Fig 15: Identifying Timing Chain Copper Links
Courtesy of FORD MOTOR CO.
19. Using the special tool, position the crankshaft.
    • Remove the special tool after crankshaft positioning.
Fig 16: Positioning Crankshaft With No. 1 Cylinder At TDC
Courtesy of FORD MOTOR CO.
20. Install the crankshaft sprocket, making sure the flange faces forward.
Fig 17: Identifying Crankshaft Sprocket Flange
Courtesy of FORD MOTOR CO.
21. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts to 10 Nm (89 lb-in).
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts to 10 Nm (89 lb-in).
Fig 18: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.
22. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
Fig 19: Identifying LH And RH Camshaft Timing Mark Position
Courtesy of FORD MOTOR CO.
23. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
Fig 20: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
24. Install the LH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
Fig 21: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
25. Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
Fig 22: Positioning LH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
26. Remove the retaining clip from the LH timing chain tensioner.
Fig 23: View Of Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
27. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
Fig 24: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
28. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
Fig 25: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
29. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
Fig 26: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
30. Remove the retaining clip from the RH timing chain tensioner.
Fig 27: View Of Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
31. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
Fig 28: Identifying Copper (Marked) Chain Links And Dots On Crankshaft Sprockets And Camshaft Sprockets
Courtesy of FORD MOTOR CO.
32. Rotate the camshaft until the lobe is in the upward position.
Fig 29: Positioning Camshaft Lobe Up
Courtesy of FORD MOTOR CO.
33. Install the special tool between the valve spring coils to prevent valve stem seal damage.
Fig 30: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the camshaft roller followers using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
34. Install the camshaft roller follower.
    1. Install the special tool.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original locations.
Fig 31: Installing Camshaft Roller Follower
Courtesy of FORD MOTOR CO.
35. Remove the special tool.
Fig 32: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
CAUTION: Only use hand tools when removing or installing the spark plugs, damage may occur to the cylinder head or spark plug.
36. Install all 8 spark plugs.
    • Tighten to 15 Nm (11 lb-ft).
Fig 33: Spark Plug
Courtesy of FORD MOTOR CO.
37. Install the crankshaft sensor ring.
Fig 34: View Of Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
38. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
Fig 35: Applying Sealant At Head-To-Block Surface & The Oil Pan-To-Block Surface
Courtesy of FORD MOTOR CO.
39. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
Fig 36: Installing Engine Front Cover Gasket
Courtesy of FORD MOTOR CO.
40. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).

    Item	Part Number	Description
    1	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    2	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    3	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    4	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    5	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    6	W706508	Stud, hex-head pilot, M8 x 1.25 x 50 - M6 x 1 x 10
    7	N808586	Stud, washer hex-head pilot, M8 x 1.25 - M6 x 1.0 x 86.35
    8	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    9	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    10	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    11	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
    12	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
    13	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
    14	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
    15	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1

Fig 37: Engine Front Cover Fastener Tightening Sequence
Courtesy of FORD MOTOR CO.
41. Loosely install the bolts, then tighten in 2 stages in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
Fig 38: Front Oil Pan Bolt Torque Sequence
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
42. Install the RH and LH engine mounts and the bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 39: Engine Mount Bolts
Courtesy of FORD MOTOR CO.
43. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
Fig 40: Locating Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
44. Using the special tools, install the front oil seal.
Fig 41: Installing Crankshaft Front Seal Using Special Tools
Courtesy of FORD MOTOR CO.
CAUTION: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
45. Apply sealant to the Woodruff key slot on the crankshaft pulley.
Fig 42: Applying Sealant To Woodruff Key Slot
Courtesy of FORD MOTOR CO.
46. Using the special tool, install the crankshaft pulley.
Fig 43: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
NOTE: Use a suitable strap wrench to hold the pulley.
47. Tighten the crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Rotate an additional 90 degrees (1/4 turn).
Fig 44: Installing Crankshaft Pulley Bolt & Washer
Courtesy of FORD MOTOR CO.
48. Position the coolant pump pulley on the coolant pump and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 45: Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
49. Install the accessory drive belt idler pulley and bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 46: Accessory Drive Belt Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
CAUTION: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
50. Apply sealant in 2 places where the engine front cover meets the cylinder head.
Fig 47: Applying Sealant At Engine Front Cover/Cylinder Head Surface
Courtesy of FORD MOTOR CO.
51. Install the new valve cover gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
Fig 48: Valve Cover Torque Sequence
Courtesy of FORD MOTOR CO.
CAUTION: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
52. Apply sealant in 2 places where the engine front cover meets the cylinder head.
Fig 49: Applying Sealant At Engine Front Cover/Cylinder Head Surface
Courtesy of FORD MOTOR CO.
53. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
Fig 50: Valve Cover Torque Sequence
Courtesy of FORD MOTOR CO.
54. Inspect the O-ring seals. Install new seals if necessary.
Fig 51: O-Ring Seals
Courtesy of FORD MOTOR CO.
55. Install the coolant bypass tube.
Fig 52: Coolant Bypass Tube
Courtesy of FORD MOTOR CO.
56. Install the ground strap on the rear of the RH cylinder head.
    1. Install the stud bolt and tighten to 25 Nm (18 lb-ft).
    2. Install the ground strap.
    3. Install the retaining nut and tighten to 10 Nm (89 lb-in).
Fig 53: Ground Strap, Stud & Nut
Courtesy of FORD MOTOR CO.
NOTE: Align the gasket locator tabs to slots in cylinder head.
57. Install the new intake manifold gaskets, intake manifold and hand-tighten the bolts at the locations shown.
Fig 54: Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
58. Install the 8 ignition coils and tighten the 8 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 55: Ignition Coils & Bolts
Courtesy of FORD MOTOR CO.
59. Install the intake manifold bracket and loosely install the bolt and the stud bolt.
Fig 56: Intake Manifold Crash Bracket Bolt
Courtesy of FORD MOTOR CO.
60. Install the thermostat.
Fig 57: Thermostat
Courtesy of FORD MOTOR CO.
61. Install the coolant outlet adapter and loosely install the 2 bolts.
Fig 58: Coolant Outlet Adapter & Bolts
Courtesy of FORD MOTOR CO.
62. Tighten the bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
Fig 59: Intake Manifold Bolt Tightening Torque Sequence
Courtesy of FORD MOTOR CO.
63. Tighten the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 60: Stud Bolt
Courtesy of FORD MOTOR CO.
64. Tighten the bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 61: Coolant Outlet Adapter & Bolts
Courtesy of FORD MOTOR CO.
65. Connect the EGR tube to the EGR valve.
    • Tighten to 40 Nm (30 lb-ft).
Fig 62: EGR Tube Nut At EGR
Courtesy of FORD MOTOR CO.
66. Connect the EGR tube-to-exhaust manifold connector.
    • Tighten to 40 Nm (30 lb-ft).
Fig 63: EGR Tube At Exhaust Manifold
Courtesy of FORD MOTOR CO.
67. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
68. Install the generator and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 64: Generator & Bolts
Courtesy of FORD MOTOR CO.
69. Connect the throttle control and the throttle position (TP) sensor electrical connector.
Fig 65: Locating Throttle Control And Throttle Position (TP) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
70. Install the generator mounting bracket and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 66: Generator Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
71. Connect the generator electrical connector.
Fig 67: Generator Electrical Connector
Courtesy of FORD MOTOR CO.
72. Connect the electrical connector to the EGR vacuum regulator solenoid.
Fig 68: EGR Vacuum Regulator Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
73. Install the generator wiring harness anchor to the LH front stud.
Fig 69: Generator Wiring Harness Anchor
Courtesy of FORD MOTOR CO.
74. Connect the crankcase ventilation tube.
Fig 70: Crankcase Ventilation Tube
Courtesy of FORD MOTOR CO.
75. Install the intake manifold shield and the 2 bolts.
    • Tighten to 12 Nm (9 lb-ft).
Fig 71: Intake Manifold Shield
Courtesy of FORD MOTOR CO.
76. Connect the 8 fuel injector electrical connectors.
Fig 72: Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
77. Connect the 8 ignition coil electrical connectors.
Fig 73: Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
78. Connect the camshaft position (CMP) sensor electrical connector.
Fig 74: Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
79. Connect the radio interference capacitor electrical connector.
Fig 75: Radio Ignition Interference Capacitor
Courtesy of FORD MOTOR CO.
80. Connect the cylinder head temperature (CHT) sensor electrical connector.
Fig 76: Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
81. Connect the ground wire to the right rear fuel rail stud.
Fig 77: Ground Wire
Courtesy of FORD MOTOR CO.
82. Install the battery cables and the bolt.
83. Install the special tool to the RH cylinder head.
Fig 78: Installing Special Tool To RH Cylinder Head
Courtesy of FORD MOTOR CO.
84. Install the special tool to the LH cylinder head.
Fig 79: Installing Special Tool To LH Cylinder Head
Courtesy of FORD MOTOR CO.
85. Using the special tool, remove the engine from the engine stand.
Fig 80: Mounting Engine On A Suitable Engine Stand
Courtesy of FORD MOTOR CO.
86. Install the engine/transmission spacer plate.
Fig 81: Engine-To-Transmission Spacer Plate
Courtesy of FORD MOTOR CO.
87. Position the flexplate and install the bolts in the sequence shown.
    • Tighten to 80 Nm (59 lb-ft).
Fig 82: Flexplate Bolt Torque Sequence
Courtesy of FORD MOTOR CO.
88. Install the engine. For additional information, refer to Engine  in the Installation portion of this section.
WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article.
89. If equipped with fire suppression system, repower the system