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Cylinder Heads: Installation

    Both cylinder heads 

    CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS .
    CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
    CAUTION: 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.
    Fig 1: Installing Head Gasket Over Dowel Pins
    G03881930Courtesy of FORD MOTOR CO.
  1. Install the head gasket over the dowel pins.
    2. CAUTION: 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.
    CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS .
    CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
    CAUTION: 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.
    Fig 2: Installing Cylinder Head On Dowels
    G03886030Courtesy of FORD MOTOR CO.
  2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
  3. Tighten the cylinder head bolts in six stages, in the sequence shown.
    • Stage 1: Tighten bolts to 40 Nm (30 lb-ft).
    • Stage 2: Tighten bolt an additional 90 degrees (1/4 turn).
    • Stage 3: Loosen the bolts a minimum of one full turn (360 degrees).
    • Stage 4: Tighten bolts to 40 Nm (30 lb-ft).
    • Stage 5: Tighten bolts an additional 90 degrees (1/4 turn).
    • Stage 6: Tighten bolts an additional 90 degrees (1/4 turn).
    Fig 3: Identifying Tightening Sequence Of Cylinder Head Bolts
    G04002324Courtesy of FORD MOTOR CO.
  4. Remove the special tools from both ends of the cylinder head.
    Fig 4: Installing/Removing Special Tools On Both Ends Of Cylinder Head
    G03885649Courtesy of FORD MOTOR CO.
    5. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
    Fig 5: Identifying Hydraulic Lash Adjusters
    G04583838Courtesy of FORD MOTOR CO.
  5. Install the hydraulic lash adjusters in their original locations.

    6. LH cylinder head 

    NOTE: Lubricate the O-ring seal with clean engine oil.
    Fig 6: Installing Oil Level Indicator Tube
    G04002032Courtesy of FORD MOTOR CO.
  6. Install the oil level indicator tube.
    • Install a new O-ring seal on the oil level indicator tube.
  7. Install the LH exhaust manifold.
    • Install a new LH exhaust manifold gasket.
    • Install the LH exhaust manifold.
    • Tighten the nuts in the sequence shown.
    Fig 7: Tightening Sequence & Torque Specification Of LH Exhaust Manifold Bolts
    G04002328Courtesy of FORD MOTOR CO.

    8. RH cylinder head 

  8. Install the RH exhaust manifold.
    • Install a new RH exhaust manifold gasket.
    • Install the RH exhaust manifold.
    • Tighten the nuts in the sequence shown.
    Fig 8: Tightening Sequence & Torque Specification Of RH Exhaust Manifold Bolts
    G04002020Courtesy of FORD MOTOR CO.

    9. 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 9: Compressing Tensioner Plunger Using Edge Of Vise
    G04001957Courtesy of FORD MOTOR CO.
  9. Compress each tensioner plunger, using an edge of a vise.
  10. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
    Fig 10: Pushing Back And Holding Ratchet Mechanism
    G04001958Courtesy of FORD MOTOR CO.
  11. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 11: Pushing Ratchet Arm Back Into Tensioner Housing
    G04001959Courtesy of FORD MOTOR CO.
  12. 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 Hole Of Tensioner Housing
    G03881578Courtesy of FORD MOTOR CO.

    13. Engines with non-ratcheting timing chain tensioners 

    CAUTION: 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 replacement of the tensioner.
  13. Inspect the RH and LH timing chain tensioners.
    • Install new tensioners as necessary.
    14. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    NOTE: LH shown; RH similar.
    Fig 13: Compressing Tensioner Plunger Using Edge Of Vise
    G03885344Courtesy of FORD MOTOR CO.
  14. Compress each tensioner plunger, using an edge of 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. Both cylinder heads 

  16. 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 15: Identifying Timing Chain Copper Links
    G03881581Courtesy of FORD MOTOR CO.
  17. Using the special tool, position the crankshaft.
    • Remove the special tool after crankshaft positioning.
    Fig 16: Positioning Crankshaft
    G03885349Courtesy of FORD MOTOR CO.
  18. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 17: Identifying Crankshaft Sprocket Flange
    G03881584Courtesy of FORD MOTOR CO.
  19. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts.
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts.
    Fig 18: Installing Timing Chain Guides
    G03885348Courtesy of FORD MOTOR CO.
  20. 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 Timing Marks
    G04583473Courtesy of FORD MOTOR CO.
  21. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 20: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03962459Courtesy of FORD MOTOR CO.
  22. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 21: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03962460Courtesy of FORD MOTOR CO.
    23. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 22: Installing LH Timing Chain Tensioner - With Torque Specification
    G03885938Courtesy of FORD MOTOR CO.
  23. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
  24. Remove the retaining clip from the LH timing chain tensioner.
    Fig 23: Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.
  25. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 24: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03948189Courtesy of FORD MOTOR CO.
  26. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 25: Aligning Copper (Marked) Link With Timing Marks On Camshaft Sprocket
    G03885941Courtesy of FORD MOTOR CO.
  27. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 26: Installing RH Timing Chain Tensioner - With Torque Specification
    G03886280Courtesy of FORD MOTOR CO.
  28. Remove the retaining clip from the RH timing chain tensioner.
    Fig 27: Removing Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.
  29. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    Fig 28: Identifying Camshaft & Crankshaft Alignment Links/Marks
    G03962922Courtesy of FORD MOTOR CO.
  30. Rotate the camshaft until the lobe is in the upward position.
    Fig 29: Positioning Lobe Of Camshaft Up
    G03881960Courtesy of FORD MOTOR CO.
  31. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 30: Installing Special Tool Between Valve Spring Coils
    G03881599Courtesy of FORD MOTOR CO.
    32. 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.
    Fig 31: Installing Camshaft Roller Followers
    G03905495Courtesy of FORD MOTOR CO.
  32. Install the camshaft roller follower.
    1. Install the special tool.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original location.
  33. Remove the special tool.
    Fig 32: Removing Special Tool
    G04002355Courtesy of FORD MOTOR CO.
  34. Install all eight spark plugs.
    Fig 33: Installing Spark Plugs
    G04002356Courtesy of FORD MOTOR CO.
  35. Install the crankshaft sensor ring.
    Fig 34: Crankshaft Sensor Ring
    G04583449Courtesy of FORD MOTOR CO.
    36. 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 cause future oil leakage.
    Fig 35: Applying Bead Of Sealant Along Head-To-Block Surface And Oil Pan-To-Block Surface
    G03886213Courtesy of FORD MOTOR CO.
  36. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
  37. 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
    G03881967Courtesy of FORD MOTOR CO.
  38. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
    Fig 37: Identifying Tightening Sequence Of Engine Front Cover Fasteners
    G04002467Courtesy of FORD MOTOR CO.
  39. Loosely install the bolts, then tighten in two stages in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 38: Identifying Tightening Sequence Of Bolts
    G03887023Courtesy of FORD MOTOR CO.
  40. Install the RH engine mount.
    Fig 39: Installing RH Engine Mount Bolts To Torque Specification
    G04002361Courtesy of FORD MOTOR CO.
  41. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
    Fig 40: Lubricating Engine Front Cover & Front Oil Seal Inner Lip
    G03881970Courtesy of FORD MOTOR CO.
  42. Using the special tools, install the front oil seal.
    Fig 41: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool
    G03885953Courtesy of FORD MOTOR CO.
    43. NOTE: If not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 42: Applying Sealant To Woodruff Key Slot On Crankshaft Pulley
    G04001916Courtesy of FORD MOTOR CO.
  43. Apply sealant to the Woodruff key slot on the crankshaft pulley.
  44. Using the special tool, install the crankshaft pulley.
    Fig 43: Installing Crankshaft Pulley Using Special Tool
    G03886064Courtesy of FORD MOTOR CO.
    45. NOTE: Use special tool 303-009 or suitable strap wrench to hold the pulley.
    Fig 44: Tightening Crankshaft Pulley Bolt
    G04002366Courtesy of FORD MOTOR CO.
  45. Tighten the crankshaft pulley bolt in four 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).
  46. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 45: Coolant Pump Pulley Bolts Torque Specification
    G04002475Courtesy of FORD MOTOR CO.
  47. Install the accessory drive belt idler pulley.
    Fig 46: Accessory Drive Belt Idler Pulley Bolt Torque Specification
    G04001929Courtesy of FORD MOTOR CO.
    48. NOTE: If not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 47: Applying Sealant In Two Places Where Engine Front Cover Meets Cylinder Head
    G04001910Courtesy of FORD MOTOR CO.
  48. Apply sealant in two places where the engine front cover meets the cylinder head.
  49. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
    Fig 48: Tightening Sequence & Torque Specification Of Valve Cover Bolts
    G04001911Courtesy of FORD MOTOR CO.
    50. NOTE: If not secured within four 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 49: Applying Sealant In Two Places Where Engine Front Cover Meets Cylinder Head
    G04001904Courtesy of FORD MOTOR CO.
  50. Apply sealant in two places where the engine front cover meets the cylinder head.
  51. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
    Fig 50: Tightening Sequence & Torque Specification Of Valve Cover Bolts
    G04001905Courtesy of FORD MOTOR CO.
  52. Inspect the O-ring seals. Install new seals if necessary.
    Fig 51: Installing O-Ring Seals
    G03948106Courtesy of FORD MOTOR CO.
  53. Install the coolant bypass tube.
    Fig 52: Installing Coolant Bypass Tube
    G04002386Courtesy of FORD MOTOR CO.
  54. Install the ground strap on the rear of the RH cylinder head.
    1. Install the stud bolt.
    2. Install the ground strap.
    3. Install the retaining nut.
    Fig 53: Installing Ground Strap On Rear Of RH Cylinder Head
    G04002387Courtesy of FORD MOTOR CO.
    55. NOTE: Align the gasket locator tabs to slots in cylinder head.
    Fig 54: Installing New Intake Manifold Gaskets
    G04002107Courtesy of FORD MOTOR CO.
  55. Install new intake manifold gaskets.
  56. Install the intake manifold and hand-tighten the bolts at the locations shown.
    Fig 55: Installing Intake Manifold
    G04002389Courtesy of FORD MOTOR CO.
  57. Install the eight ignition coils and tighten the eight bolts.
    Fig 56: Ignition Coil Bolts Torque Specification
    G04001862Courtesy of FORD MOTOR CO.
  58. Install the crash bracket and loosely install the bolt and the stud.
    Fig 57: Installing Bolt & Stud
    G03881486Courtesy of FORD MOTOR CO.
  59. Install the thermostat.
    Fig 58: Installing Thermostat
    G04002392Courtesy of FORD MOTOR CO.
  60. Install the coolant outlet adapter and loosely install the bolts.
    Fig 59: Installing Coolant Outlet Adapter
    G04002104Courtesy of FORD MOTOR CO.
  61. Tighten the bolts in the sequence shown.
    Fig 60: Tightening Sequence & Torque Specification Of Intake Manifold Bolts
    G04002394Courtesy of FORD MOTOR CO.
  62. Tighten the stud.
    Fig 61: Stud Torque Specification
    G04001865Courtesy of FORD MOTOR CO.
  63. Tighten the bolts.
    Fig 62: Tightening Bolts To Torque Specification
    G04002396Courtesy of FORD MOTOR CO.
  64. Install the throttle body and tighten the bolts.
    Fig 63: Throttle Body Bolts Torque Specification
    G03882005Courtesy of FORD MOTOR CO.
  65. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
    Fig 64: Connecting Exhaust Gas Recirculation Tube To EGR Valve
    G04002399Courtesy of FORD MOTOR CO.
  66. Connect the EGR tube-to-exhaust manifold connector.
    Fig 65: Connecting EGR Tube-To-Exhaust Manifold Connector
    G04002400Courtesy of FORD MOTOR CO.
  67. Position the fuel charging wiring at two locations at the back of the intake manifold.
  68. Install the generator.
    Fig 66: Generator Bolts Torque Specification
    G04002401Courtesy of FORD MOTOR CO.
  69. Connect the throttle control and the throttle position (TP) sensor electrical connector.
    Fig 67: Locating Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  70. Install the generator mounting bracket.
    Fig 68: Generator Mounting Bracket Bolts Torque Specification
    G04002498Courtesy of FORD MOTOR CO.
  71. Connect the generator electrical connector, generator cable and harness pin-type retainer.
    Fig 69: Connecting Generator Electrical Connector, Generator Cable And Harness Pin-Type Retainer
    G04002499Courtesy of FORD MOTOR CO.
  72. Connect the electrical connector to the EGR vacuum regulator solenoid.
    Fig 70: Connecting Electrical Connector To EGR Vacuum Regulator Solenoid
    G04002500Courtesy of FORD MOTOR CO.
  73. Install the generator wiring harness anchor to the LH front stud.
    Fig 71: Installing Generator Wiring Harness Anchor To LH Front Stud
    G04002208Courtesy of FORD MOTOR CO.
  74. Connect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 72: Connecting Engine Coolant Temperature Sensor Electrical Connector
    G04001853Courtesy of FORD MOTOR CO.
  75. Connect the crankcase ventilation tube.
    Fig 73: Connecting Crankcase Ventilation Tube
    G04002088Courtesy of FORD MOTOR CO.
  76. Install the EGR tube heat shield.
    Fig 74: Installing EGR Tube Heat Shield
    G03881459Courtesy of FORD MOTOR CO.
  77. Connect the eight fuel injector electrical connectors.
    Fig 75: Connecting Fuel Injector Electrical Connectors
    G03881457Courtesy of FORD MOTOR CO.
  78. Connect the eight ignition coil electrical connectors.
    Fig 76: Connecting Ignition Coil Electrical Connectors
    G04001835Courtesy of FORD MOTOR CO.
  79. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 77: Connecting Camshaft Position Sensor Electrical Connector
    G04002211Courtesy of FORD MOTOR CO.
  80. Connect the radio interference capacitor electrical connector.
    Fig 78: Connecting Radio Interference Capacitor Electrical Connector
    G04002412Courtesy of FORD MOTOR CO.
  81. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 79: Connecting Cylinder Head Temperature Sensor Electrical Connector
    G04002207Courtesy of FORD MOTOR CO.
  82. Connect the ground wire to the right rear fuel rail stud.
    Fig 80: Connecting Ground Wire To Right Rear Fuel Rail Stud
    G04002415Courtesy of FORD MOTOR CO.
  83. Install the battery cables and the bolt.
  84. Install the RH and LH lifting brackets.
    Fig 81: Installing Lifting Bracket
    G04002080Courtesy of FORD MOTOR CO.
  85. Remove the engine from the engine stand.
    Fig 82: Removing Engine From Engine Stand
    G03882120Courtesy of FORD MOTOR CO.
  86. Install the engine/transmission spacer plate.
    Fig 83: Installing Engine/Transmission Spacer Plate
    G03882121Courtesy of FORD MOTOR CO.
  87. Position the flexplate and install the bolts in the sequence shown.
    Fig 84: Tightening Sequence & Torque Specification Of Flexplate Bolts
    G04002514Courtesy of FORD MOTOR CO.
  88. Install the engine. For additional information, refer to ENGINE .
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