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Cylinder Head

SPECIAL TOOL DESCRIPTION

G03886005
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
G03920070
 Compressor, Valve Spring 303-1039
G03920369
 Locking Tool, Camshaft Phaser Sprocket 303-1046
G03919900
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
G03886827
 Installer, Crankshaft Front Seal 303-635
G03886455
 Holding Tool, Crankshaft 303-448 (T93P-6303-A)
G03920628
 Installer, Front Cover Seal 303-335 (T88T-6701-A)
G03886715
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent (yellow color) WSS-M97B51-A1
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Motorcraft Metal Surface Prep ZC-31 -
Silicone Gasket Remover ZC-30 -
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA -

    All cylinder heads 

    CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
    CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    NOTE: Do not turn the crankshaft until instructed to do so.
    NOTE: LH shown, RH similar.
    Fig 1: Installing Cylinder Head Gaskets And Cylinder Heads
    G03920395Courtesy of FORD MOTOR CO.
  1. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
    2. NOTE: RH shown, LH similar.
    Fig 2: Identifying Tighten Sequence Of Cylinder Head Bolts
    G03920396Courtesy of FORD MOTOR CO.
  2. Tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.

    3. LH cylinder head 

  3. Remove the special tool from the LH cylinder head.
    Fig 3: Removing Special Tool Onto LH Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  4. Install the hydraulic lash adjusters into the LH cylinder head.
    • Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
    Fig 4: Installing Hydraulic Lash Adjusters
    G03920399Courtesy of FORD MOTOR CO.
  5. Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 5: Identifying Bolt Tightening Sequence Of LH Exhaust Manifold
    G03920090Courtesy of FORD MOTOR CO.

    6. RH cylinder head 

  6. Remove the special tool from the RH cylinder head.
    Fig 6: Removing Special Tool Onto RH Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
  7. Install the hydraulic lash adjusters into the RH cylinder head.
    • Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
    Fig 7: Installing Hydraulic Lash Adjusters
    G03920399Courtesy of FORD MOTOR CO.
  8. Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 8: Identifying Bolt Tightening Sequence Of RH Exhaust Manifold
    G03920092Courtesy of FORD MOTOR CO.
  9. Install the coolant tube and the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 9: Installing Coolant Tube
    G03920263Courtesy of FORD MOTOR CO.

    10. All cylinder heads 

  10. Install the LH and RH camshafts.
    • Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
    11. NOTE: LH shown, RH similar.
    Fig 10: Identifying Camshaft Bearing Cap Bolt Tightening Sequences
    G03919956Courtesy of FORD MOTOR CO.
  11. Install the LH and RH camshaft bearing caps in their original locations.
    • Lubricate the camshaft bearing caps with clean engine oil.
    • Position the front camshaft bearing cap.
    • Position the remaining camshaft bearing caps.
    • Install the bolts loosely.
    • Tighten to 10 Nm (89 lb-in) in the sequence shown.
    12. CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    NOTE: LH shown, RH similar.
    Fig 11: Installing VCT Phaser Sprockets
    G03919961Courtesy of FORD MOTOR CO.
  12. Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight.
    13. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
    NOTE: LH shown, RH similar.
    Fig 12: Tightening VCT Phaser Sprocket Bolts
    G03919955Courtesy of FORD MOTOR CO.
  13. Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    14. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
    Fig 13: Compressing Tensioner Plunger Using Edge Of Vise
    G03885344Courtesy of FORD MOTOR CO.
  14. Compress the tensioner plunger, using a vise.
  15. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 14: Installing Retaining Clip On Tensioner
    G03881580Courtesy of FORD MOTOR CO.
  16. Remove the tensioner from the vise.
  17. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
    Fig 15: Marking Links When Copper Link Is Not Visible
    G03885317Courtesy of FORD MOTOR CO.
  18. Using the special tool, position the crankshaft keyway at the 11 o'clock position.
    Fig 16: Positioning Crankshaft To 11 O'Clock Position
    G03919963Courtesy of FORD MOTOR CO.
  19. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 17: Installing Crankshaft Sprocket
    G03919967Courtesy of FORD MOTOR CO.
  20. Install the 4 bolts and the LH and RH timing chain guides.
    • Tighten to 10 Nm (89 lb-in).
    Fig 18: Identifying LH And RH Timing Chain Guides
    G03933858Courtesy of FORD MOTOR CO.
  21. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
    Fig 19: Aligning Crankshaft Sprocket Timing Mark And LH Timing Chain Link
    G03919969Courtesy of FORD MOTOR CO.
    22. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
    Fig 20: Identifying Timing Mark & Copper (Marked) Chain Links
    G03919970Courtesy of FORD MOTOR CO.
  22. Position the timing chain on the VCT phaser sprocket with the timing mark positioned between the 2 copper (marked) chain links.
    23. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 21: Installing LH Timing Chain Tensioner Arm & LH Timing Chain Tensioner
    G03919950Courtesy of FORD MOTOR CO.
  23. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
    • Tighten to 25 Nm (18 lb-ft).
  24. Remove the retaining clip from the LH timing chain tensioner.
    Fig 22: Removing Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.
  25. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
    Fig 23: Aligning Crankshaft Sprocket Timing Mark And RH Timing Chain Link
    G03919973Courtesy of FORD MOTOR CO.
    26. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
    NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.
    Fig 24: Positioning RH Timing Chain On VCT Phaser Sprocket
    G03919974Courtesy of FORD MOTOR CO.
  26. Position the RH timing chain on the VCT phaser sprocket with the timing mark positioned between the 2 copper (marked) chain links.
  27. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 25: Installing RH Timing Chain Tensioner Arm & Timing Chain Tensioner
    G03919951Courtesy of FORD MOTOR CO.
  28. Remove the retaining clip from the RH timing chain tensioner.
    Fig 26: Removing Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.
  29. As a post-check, verify correct alignment of all timing marks.
    Fig 27: Checking Correct Alignment Of All Timing Marks
    G03919977Courtesy of FORD MOTOR CO.
  30. Install the crankshaft sensor ring on the crankshaft.
    Fig 28: Installing Crankshaft Sensor Ring
    G04583449Courtesy of FORD MOTOR CO.
  31. Using the special tool, install all of the camshaft roller followers.
    • Lubricate the camshaft roller followers with clean engine oil prior to installation.
    Fig 29: Compressing Spring Using Special Tool
    G03919948Courtesy of FORD MOTOR CO.
    32. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
    Fig 30: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface
    G03919915Courtesy of FORD MOTOR CO.
  32. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
  33. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
    Fig 31: Installing Engine Front Cover
    G03881967Courtesy of FORD MOTOR CO.
  34. Tighten the engine front cover fasteners in sequence in 2 stages.

    Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

    Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

    Fig 32: Identifying Tighten Sequence Of Engine Front Cover Fasteners
    G03933991Courtesy of FORD MOTOR CO.
    35. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  35. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  36. Install the 4 front oil pan bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    Fig 33: Identifying Tightening Sequence Of Front Oil Pan/Cover Bolts
    G03920544Courtesy of FORD MOTOR CO.
    37. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 34: Identifying Silicone Gasket Application Points
    G03919863Courtesy of FORD MOTOR CO.
  37. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
    38. CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.
    Fig 35: Identifying Tightening Sequence Of RH Valve Cover Bolts
    G03919864Courtesy of FORD MOTOR CO.
  38. Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    39. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  39. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    40. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 36: Identifying Silicone Gasket Application Points
    G03919870Courtesy of FORD MOTOR CO.
  40. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
    41. CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.
    Fig 37: Identifying Tightening Sequence Of RH Valve Cover Bolts
    G03919871Courtesy of FORD MOTOR CO.
  41. Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
  42. Install the oil level indicator tube and the bolt.
    • Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
    • Tighten to 10 Nm (89 lb-in).
    Fig 38: Installing Oil Level Indicator Tube
    G03933683Courtesy of FORD MOTOR CO.
  43. Position the RH engine support insulator and install the 3 bolts.
    • Tighten to 63 Nm (46 lb-ft).
    Fig 39: Installing RH Engine Support Insulator
    G03933620Courtesy of FORD MOTOR CO.
  44. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 40: Lubricating Engine Front Cover & Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  45. Using the special tools, install a new crankshaft front seal into the engine front cover.
    Fig 41: Installing Crankshaft Front Seal Into Engine Front Cover
    G03934000Courtesy of FORD MOTOR CO.
    46. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 42: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  46. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  47. Using the special tool, install the crankshaft pulley.
    Fig 43: Installing Crankshaft Pulley
    G03920552Courtesy of FORD MOTOR CO.
  48. Tighten the new 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: Tighten an additional 90 degrees.
    Fig 44: Installing Crankshaft Pulley Bolt & Washer
    G04672695Courtesy of FORD MOTOR CO.
    49. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
    Fig 45: Installing LH CMP Sensor
    G03919989Courtesy of FORD MOTOR CO.
  49. Install the LH camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    50. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
    Fig 46: Installing RH CMP Sensor
    G03920013Courtesy of FORD MOTOR CO.
  50. Install the RH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
  51. Position the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 47: Installing Crankshaft Position (CKP) Sensor
    G03920231Courtesy of FORD MOTOR CO.
  52. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 48: Installing Accessory Drive Belt Tensioner
    G03920234Courtesy of FORD MOTOR CO.
  53. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 49: Installing Coolant Pump Pulley And Accessory Drive Belt Idler Pulley
    G03933688Courtesy of FORD MOTOR CO.
  54. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
  55. Connect the CKP sensor electrical connector.
    Fig 50: Connecting CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
    56. NOTE: LH shown, RH similar.
    Fig 51: Installing Ignition Coils
    G03920226Courtesy of FORD MOTOR CO.
  56. Install the 8 ignition coils and the 8 bolts.
    • Tighten to 6 Nm (53 lb-in).
  57. Install the LH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 52: Installing LH Radio Ignition Interference Capacitor
    G03920225Courtesy of FORD MOTOR CO.
  58. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 53: Connecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  59. Connect the 4 RH ignition coil electrical connectors.
    Fig 54: Connecting RH Ignition Coil Electrical Connectors
    G03920223Courtesy of FORD MOTOR CO.
  60. Connect the electrical connector retainer to the coolant tube.
    Fig 55: Connecting Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  61. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 56: Connecting Engine Wiring Harness Retainers To RH Valve Cover
    G03920221Courtesy of FORD MOTOR CO.
  62. Connect the RH VCT solenoid electrical connector.
    Fig 57: Connecting RH VCT Solenoid Electrical Connector
    G03920220Courtesy of FORD MOTOR CO.
  63. Install the RH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 58: Installing RH Radio Ignition Interference Capacitor
    G03920219Courtesy of FORD MOTOR CO.
  64. Connect the RH CMP sensor electrical connector.
    Fig 59: Connecting RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  65. Using a suitable floor crane, remove the engine from the engine stand.
  66. Install the flexplate and the 8 bolts in the sequence shown.
    • Tighten to 80 Nm (59 lb-ft).
    Fig 60: Identifying Flexplate Bolt Tightening Sequence
    G03920141Courtesy of FORD MOTOR CO.
  67. Install the engine. For additional information, refer to ENGINE .
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