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Home >> Lincoln >> 2004 >> Aviator RWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> Installation >> Cylinder Heads

Cylinder Heads

Fig 1: Identifying Special Tool(s)
G03264765Courtesy of FORD MOTOR CO.
MATERIALS

Item Specification
SAE 5W-20 Super Premium Synthetic Blend Engine Oil XO-5W20-QSP or equivalent WSS-M2C153-H
Metal Surface Cleaner F4AZ-19A536-RA or equivalent WSE-M5B392-A
Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSE-M4G323-A4
Silicone Brake Caliper Grease and Dielectric Compound XG-3 or equivalent ESE-M1C171-A
NOTE: Before cylinder head installation, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

    ALL VEHICLES 

  1. Install new cylinder head gaskets.
    Fig 2: Installing New Cylinder Head Gaskets
    G03264766Courtesy of FORD MOTOR CO.
    2. NOTE: LH shown; RH similar.
    NOTE: Lubricate the new bolt heads and threads. Use clean engine oil.
    Fig 3: Tightening LH And RH Cylinder Head Bolts In Sequence
    G03264767Courtesy of FORD MOTOR CO.
  2. Install the LH and RH cylinder heads and tighten the bolts in six stages in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Loosen the bolts a minimum of one full turn.
    • Stage 4: Tighten to 40 Nm (30 lb-ft).
    • Stage 5: Tighten an additional 90 degrees.
    • Stage 6: Tighten an additional 90 degrees.
    3. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
    Fig 4: Installing Hydraulic Lash In Original Locations For Both Cylinder Heads
    G03264768Courtesy of FORD MOTOR CO.
  3. Install the hydraulic lash adjusters in their original locations for both cylinder heads.

    4. 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.
    Fig 5: Compressing Each Tensioner Plunger
    G03264769Courtesy of FORD MOTOR CO.
  4. Compress each tensioner plunger, using an edge of a vise.
  5. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
    Fig 6: Pushing Back And Hold Ratchet Mechanism
    G03264770Courtesy of FORD MOTOR CO.
  6. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 7: Pushing Ratchet Arm Back Into Tensioner Housing
    G03264771Courtesy of FORD MOTOR CO.
  7. 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 8: Installing Paper Clip Into Hole Of Each Tensioner Housing
    G03264772Courtesy of FORD MOTOR CO.

    8. ENGINES WITH NON-RATCHETING TIMING CHAIN TENSIONERS 

  8. Compress the tensioner plunger, using a vise.
    Fig 9: Compressing Tensioner Plunger
    G03264773Courtesy of FORD MOTOR CO.
  9. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 10: Installing A Retaining Clip On Tensioner To Hold Plunger
    G03264774Courtesy of FORD MOTOR CO.
  10. Remove the tensioner from the vise.

    11. ALL ENGINES 

  11. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
    Fig 11: Marking One Link On One End And One Link On The Other End To Use As Timing Marks
    G03264775Courtesy of FORD MOTOR CO.
  12. Install the timing chain guides.
    Fig 12: Installing Timing Chain Guides
    G03264776Courtesy of FORD MOTOR CO.
  13. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is at approximately the 11 o'clock position.
    Fig 13: Rotating LH Camshaft Timing Sprocket
    G03264777Courtesy of FORD MOTOR CO.
    14. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
    Fig 14: Positioning Crankshaft
    G03264778Courtesy of FORD MOTOR CO.
  14. Using the special tool, position the crankshaft.
  15. Install the crankshaft sprocket with the flange facing forward.
    Fig 15: Installing Crankshaft Sprocket With Flange Facing Forward
    G03264779Courtesy of FORD MOTOR CO.
  16. Install the LH and RH timing chains onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
    Fig 16: Installing LH And RH Timing Chains Onto Crankshaft Sprocket
    G03264780Courtesy of FORD MOTOR CO.
    17. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
  17. Position the LH and RH timing chains on the camshaft sprockets. Make sure the copper-colored links align with the camshaft sprocket timing marks.
  18. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the bolts.
    Fig 17: Positioning LH And RH Timing Chain Tensioner Arms On Dowel Pins
    G03264781Courtesy of FORD MOTOR CO.

    19. ENGINES WITH RATCHETING TIMING CHAIN TENSIONERS 

  19. Remove the retaining clip from the timing chain tensioners.
    Fig 18: Removing Retaining Clip From Timing Chain Tensioners
    G03264782Courtesy of FORD MOTOR CO.

    20. ENGINES WITH NON-RATCHETING TIMING CHAIN TENSIONERS 

  20. Remove the retaining clips from the timing chain tensioners.
    Fig 19: Removing Retaining Clips From Timing Chain Tensioners
    G03264783Courtesy of FORD MOTOR CO.

    21. ALL ENGINES 

  21. As a post-check, verify correct alignment of all timing marks.
    Fig 20: Aligning Timing Marks
    G03264784Courtesy of FORD MOTOR CO.
  22. Position the crankshaft sensor ring on the crankshaft.
    Fig 21: Positioning Crankshaft Sensor Ring On Crankshaft
    G03264785Courtesy of FORD MOTOR CO.
    23. NOTE: If the engine front cover is not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
    Fig 22: Applying Silicone Gasket And Sealant
    G03264786Courtesy of FORD MOTOR CO.
  23. Apply silicone gasket and sealant in the locations shown.
  24. Install the engine front cover and tighten the bolts in the sequence shown.
    Fig 23: Engine Front Cover Bolt Tightening Sequence
    G03264787Courtesy of FORD MOTOR CO.
  25. Install the four oil pan bolts and tighten in the sequence shown in three stages.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    • Stage 3: Tighten an additional 60 degrees.
    Fig 24: Installing Four Oil Pan Bolts
    G03264788Courtesy of FORD MOTOR CO.
    26. CAUTION: If reusing the roller followers, install them in their original locations.
  26. Position the piston of the cylinder in which the roller followers are being installed at the bottom of the stroke and the camshaft lobe at the base circle.
  27. Using the special tool, compress the intake valve spring and install the roller follower.
    Fig 25: Compressing Intake Valve Spring
    G03264789Courtesy of FORD MOTOR CO.
  28. Using the special tool, compress the exhaust valve spring and install the roller follower.
    Fig 26: Compressing Exhaust Valve Spring
    G03264790Courtesy of FORD MOTOR CO.
  29. Repeat the above steps to install all of the roller followers.
    30. NOTE: If the valve cover is not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
    Fig 27: Applying Silicone Gasket And Sealant
    G03264791Courtesy of FORD MOTOR CO.
  30. Apply silicone gasket and sealant in the locations shown.
    31. NOTE: RH shown; LH similar.
    Fig 28: Valve Cover Bolt Tightening Sequence
    G03264792Courtesy of FORD MOTOR CO.
  31. Install the valve covers and tighten the bolts in the sequence shown.
  32. Install the belt idler pulley.
    Fig 29: Installing Belt Idler Pulley
    G03264793Courtesy of FORD MOTOR CO.
  33. Lubricate the front oil seal and the engine front cover with clean engine oil.
    Fig 30: Lubricating Front Oil Seal And Engine Front Cover
    G03264794Courtesy of FORD MOTOR CO.
  34. Using the special tools, install the front oil seal.
    Fig 31: Installing Front Oil Seal
    G03264795Courtesy of FORD MOTOR CO.
  35. Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
    Fig 32: Applying Silicone Gasket And Sealant To Woodruff Key On Crankshaft Pulley
    G03264796Courtesy of FORD MOTOR CO.
  36. Using the special tool, install the crankshaft pulley.
    Fig 33: Installing Crankshaft Pulley
    G03264797Courtesy of FORD MOTOR CO.
  37. Install the bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in four stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen the bolt.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 34: Installing Crankshaft Pulley
    G03264798Courtesy of FORD MOTOR CO.
  38. Install the coolant pump pulley.
    Fig 35: Installing Coolant Pump Pulley
    G03264799Courtesy of FORD MOTOR CO.
  39. Install the power steering pump and the three bolts.
    Fig 36: Installing Power Steering Pump
    G03264800Courtesy of FORD MOTOR CO.
    40. NOTE: Install a new O-ring and lubricate with clean engine oil.
    Fig 37: Installing A New O-Ring And Lubricate With Clean Engine Oil
    G03264801Courtesy of FORD MOTOR CO.
  40. Install the oil level indicator tube.
    • Install the oil level indicator tube in the engine block.
    • Install the fasteners and tighten to 10 Nm (89 lb-in).
    41. NOTE: LH shown; RH similar.
    Fig 38: Installing New Exhaust Manifold Gaskets
    G03264802Courtesy of FORD MOTOR CO.
  41. Install the exhaust manifolds.
    1. Install new exhaust manifold gaskets.
    2. Install the exhaust manifolds.
    3. Install the 16 nuts.
  42. Install the bolt and the coolant bypass tube.
    Fig 39: Installing Bolt And Coolant Bypass Tube
    G03264803Courtesy of FORD MOTOR CO.
    43. NOTE: Upper intake shown removed for clarity.
    Fig 40: Installing Upper And Lower Intake
    G03264804Courtesy of FORD MOTOR CO.
  43. Install the upper and lower intake.
    • Tighten all fasteners in the sequence shown to 10 Nm (89 lb-in).
  44. Install the upper-to-lower intake bracket and the nuts.
    Fig 41: Installing Upper-To-Lower Intake Bracket
    G03264805Courtesy of FORD MOTOR CO.
  45. Install the coolant hose retainers on the RH valve cover.
    Fig 42: Installing Coolant Hose Retainers On RH Valve Cover
    G03264806Courtesy of FORD MOTOR CO.
    46. NOTE: RH shown; LH similar.
    Fig 43: Installing Engine Lifting Eyes
    G03264807Courtesy of FORD MOTOR CO.
  46. Install the engine lifting eyes.
  47. Install the eight ignition coils.
    Fig 44: Installing Ignition Coils
    G03264808Courtesy of FORD MOTOR CO.
  48. Install the crossover tube.
    1. Install the crossover tube and the nuts.
    2. Connect the coolant hose.
    Fig 45: Installing Crossover Tube
    G03264809Courtesy of FORD MOTOR CO.
  49. Install the generator and the bolts.
    Fig 46: Installing Generator
    G03264810Courtesy of FORD MOTOR CO.
  50. Install the generator support bracket and the bolts.
    Fig 47: Installing Generator Support Bracket
    G03264811Courtesy of FORD MOTOR CO.
  51. Rotate the belt tensioner clockwise and install the accessory drive belt.
    Fig 48: Installing Accessory Drive Belt
    G03264812Courtesy of FORD MOTOR CO.
  52. Install the coolant bypass-to-thermostat housing hose.
    Fig 49: Installing Coolant Bypass-To-Thermostat Housing Hose
    G03264813Courtesy of FORD MOTOR CO.
  53. Install the upper radiator hose.
    Fig 50: Installing Upper Radiator Hose
    G03264814Courtesy of FORD MOTOR CO.
  54. Position the engine wiring harness on the engine.
  55. Connect the A/C compressor and the crankshaft position (CKP) sensor electrical connectors.
    Fig 51: Connecting A/C Compressor And Crankshaft Position (CKP) Sensor Electrical Connectors
    G03264815Courtesy of FORD MOTOR CO.
  56. Connect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 52: Connecting Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03264816Courtesy of FORD MOTOR CO.
  57. Connect the two harness retainers to the RH valve cover studs.
    Fig 53: Connecting Two Harness Retainers To RH Valve Cover Studs
    G03264817Courtesy of FORD MOTOR CO.
  58. Connect the throttle position (TP) sensor and the idle air control (IAC) sensor electrical connectors.
    Fig 54: Connecting Throttle Position (TP) Sensor And Idle Air Control (IAC) Sensor Electrical Connectors
    G03264818Courtesy of FORD MOTOR CO.
  59. Connect the RH radio interference capacitor electrical connector and the pin-type retainer.
    Fig 55: Connecting RH Radio Interference Capacitor Electrical Connector And The Pin-Type Retainer
    G03264819Courtesy of FORD MOTOR CO.
  60. Install the positive crankcase ventilation (PCV) tube.
    Fig 56: Installing Positive Crankcase Ventilation (PCV) Tube
    G03264820Courtesy of FORD MOTOR CO.
  61. Connect the PCV electrical connector.
    Fig 57: Connecting PCV Electrical Connector
    G03264821Courtesy of FORD MOTOR CO.
  62. Connect the cylinder head temperature (CHT) sensor electrical connector and the two pin-type retainers.
    Fig 58: Connecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03264822Courtesy of FORD MOTOR CO.
  63. Connect the exhaust gas recirculation (EGR) system module tube to the exhaust manifold.
    Fig 59: Connecting Exhaust Gas Recirculation (EGR) System Module Tube To Exhaust Manifold
    G03264823Courtesy of FORD MOTOR CO.
  64. Connect the intake manifold runner control (IMRC) electrical connector.
    Fig 60: Connecting Intake Manifold Runner Control (IMRC) Electrical Connector
    G03264824Courtesy of FORD MOTOR CO.
  65. Connect the wiring harness retainer to the stud on the cylinder head.
    Fig 61: Connecting Wiring Harness Retainer To Stud On Cylinder Head
    G03264825Courtesy of FORD MOTOR CO.
  66. Connect the KS electrical connector and the pin-type retainer.
    Fig 62: Connecting KS Electrical Connector And Pin-Type Retainer
    G03264826Courtesy of FORD MOTOR CO.
  67. Connect the pin-type retainers to the back of the engine in the locations shown.
    Fig 63: Connecting Pin-Type Retainers To Back Of Engine
    G03264827Courtesy of FORD MOTOR CO.
  68. Connect the oil pressure sensor electrical connector.
    Fig 64: Connecting Oil Pressure Sensor Electrical Connector
    G03264828Courtesy of FORD MOTOR CO.
  69. Connect the camshaft position (CMP) sensor electrical connector and the two retainers to the valve cover.
    Fig 65: Connecting Camshaft Position (CMP) Sensor Electrical Connector
    G03264829Courtesy of FORD MOTOR CO.
  70. Install the fuel charging wiring harness retainers to the fuel injection supply manifold.
    Fig 66: Installing Fuel Charging Wiring Harness
    G03264830Courtesy of FORD MOTOR CO.
  71. Connect the eight fuel injector electrical connectors.
    Fig 67: Connecting Fuel Injector Electrical Connectors
    G03264831Courtesy of FORD MOTOR CO.
  72. Connect the radio interference capacitor electrical connector.
    Fig 68: Connecting Radio Interference Capacitor Electrical Connector
    G03264832Courtesy of FORD MOTOR CO.
  73. Connect the eight ignition coil electrical connectors.
    Fig 69: Connecting Ignition Coil Electrical Connectors
    G03264833Courtesy of FORD MOTOR CO.
    74. NOTE: RH shown; LH similar.
    Fig 70: Installing RH And LH Coil Covers
    G03264834Courtesy of FORD MOTOR CO.
  74. Install the RH and LH coil covers.
  75. Position the vacuum harness and connect it to the intake manifold.
    Fig 71: Positioning Vacuum Harness And Connect To Intake Manifold
    G03264835Courtesy of FORD MOTOR CO.
  76. Connect the electrical connector and the vacuum hose to the fuel pressure sensor.
    Fig 72: Connecting Electrical Connector And Vacuum Hose To Fuel Pressure Sensor
    G03264836Courtesy of FORD MOTOR CO.
  77. Install the battery cable harness and the bolt to the RH engine mount.
    Fig 73: Installing Battery Cable Harness And Bolt To RH Engine Mount
    G03264837Courtesy of FORD MOTOR CO.
  78. Connect the two retainers to the A/C compressor.
    Fig 74: Connecting Two Retainers To A/C Compressor
    G03264838Courtesy of FORD MOTOR CO.
  79. Connect the two retainers to the engine front cover studs.
    Fig 75: Connecting Two Retainers To Engine Front Cover Studs
    G03264839Courtesy of FORD MOTOR CO.
  80. Connect the electrical connector and the battery cable to the alternator.
    Fig 76: Connecting Electrical Connector And Battery Cable To Alternator
    G03264840Courtesy of FORD MOTOR CO.
  81. Connect the battery cable harness ground.
    Fig 77: Connecting Battery Cable Harness Ground
    G03264841Courtesy of FORD MOTOR CO.
  82. Position the power steering reservoir and install the two bolts and the pin-type retainer.
    Fig 78: Installing Power Steering Reservoir Bolts And Pin-Type Retainer
    G03264842Courtesy of FORD MOTOR CO.
  83. Install the remaining bolt and the hose to the power steering reservoir.
    Fig 79: Installing Remaining Bolt And Hose To Power Steering Reservoir
    G03264843Courtesy of FORD MOTOR CO.
    84. NOTE: LH shown, RH similar.
    Fig 80: Installing LH And RH Engine Mounts
    G03264844Courtesy of FORD MOTOR CO.
  84. Install the LH and RH engine mounts.
    • Tighten to 70 Nm (52 lb-ft).
  85. Remove the engine from the stand.
    Fig 81: Removing Engine From Stand
    G03264845Courtesy of FORD MOTOR CO.
  86. Install the spacer plate and the flexplate.
    Fig 82: Installing Spacer Plate And Flexplate
    G03264846Courtesy of FORD MOTOR CO.
  87. Install the engine. For additional information, refer to ENGINE .
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