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Cylinder Head

SPECIAL TOOL(S)

G04627499Courtesy of FORD MOTOR CO.
 Remover/Installer, Cylinder Head
303-572 (T97T-6000-A)
G04627500Courtesy of FORD MOTOR CO.
 Compressor, Valve Spring
303-1039
G04627501Courtesy of FORD MOTOR CO.
 Locking Tool, Camshaft Phaser Sprocket
303-1046
G04627502Courtesy of FORD MOTOR CO.
 Installer, Crankshaft Vibration Damper
303-102 (T74P-6316-B)
G04627503Courtesy of FORD MOTOR CO.
 Installer, Crankshaft Front Seal
303-635
G04627504Courtesy of FORD MOTOR CO.
 Holding Tool, Crankshaft
303-448 (T93P-6303-A)
G04627505Courtesy of FORD MOTOR CO.
 Installer, Front Cover Seal
303-335 (T88T-6701-A)
G04627506Courtesy of FORD MOTOR CO.
 Modular Engine Lift Bracket
303-F047 (014-00073) or equivalent
MATERIALS

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); 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:
    1. Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
    2. The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
    3. The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    NOTE:
    1. Do not turn the crankshaft until instructed to do so.
    2. LH shown, RH similar.
    Fig 1: Locating Cylinder Head And Gaskets Using Special Tool (303-1040)
    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.
  2. Tighten the bolts in 3 stages, in the sequence shown in Fig 2.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
      Fig 2: Identifying Tightening Sequence Of Bolts
      G04627508Courtesy of FORD MOTOR CO.

    3. LH cylinder head 

  3. Remove the special tool from the LH cylinder head.
    Fig 3: Identifying Special Tool Onto 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: Identifying 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 in Fig 5.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 5: Identifying Tightening Sequence Of LH Exhaust Manifold Bolts
      G04627511Courtesy of FORD MOTOR CO.

    6. RH cylinder head 

  6. Remove the special tool from the RH cylinder head.
    Fig 6: Identifying Special Tool On 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: Identifying 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 in Fig 8.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 8: Identifying Tightening Sequence Of RH Exhaust Manifold Bolts
      G04627514Courtesy of FORD MOTOR CO.
  9. Install the coolant tube and the stud bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 9: Identifying Coolant Tube Stud Bolt
      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.
  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 N.m (89 lb-in) in the sequence shown in Fig 10.
      Fig 10: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequence
      G03919956Courtesy of FORD MOTOR CO.
    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: Identifying Camshaft Phaser And Sprocket Assembly Bolt
    G03919961Courtesy of FORD MOTOR CO.
  12. Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight.
    13. CAUTION:
    1. Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    2. 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.
  13. Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 12: Identifying Special Sprocket Phaser Tool
      G03919955Courtesy of FORD MOTOR CO.
    14. CAUTION:
    1. Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    2. 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
    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: Identifying 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: Locating Timing Chain Marks
    G03885317Courtesy of FORD MOTOR CO.
  18. Using the special tool, position the crankshaft keyway at the 11 o'clock position.
    Fig 16: Positioning Crankshaft With Special Tool (303-448)
    G03919963Courtesy of FORD MOTOR CO.
  19. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 17: Identifying Crankshaft Sprocket
    G03919967Courtesy of FORD MOTOR CO.
  20. Install the 4 bolts and the LH and RH timing chain guides.
    • Tighten to 10 N.m (89 lb-in).
      Fig 18: Identifying 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 Copper Links Of Timing Chain On VCT Phaser Sprocket
    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.
  23. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 21: Identifying LH Timing Chain Tensioner & Tensioner Arm
      G03919950Courtesy of FORD MOTOR CO.
  24. Remove the retaining clip from the LH timing chain tensioner.
    Fig 22: View Of Retaining Clip AndTiming Chain Tensioner
    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:
    1. The lower half of the timing chain must be positioned above the tensioner arm dowel.
    2. The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.
    Fig 24: Identifying Mark Of RH Timing Chain On VCT Phaser Sprocket
    G04627530Courtesy 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 N.m (18 lb-ft).
      Fig 25: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
      G03919951Courtesy of FORD MOTOR CO.
  28. Remove the retaining clip from the RH timing chain tensioner.
    Fig 26: View Of Retaining Clip AndTiming Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  29. As a post-check, verify correct alignment of all timing marks.
    Fig 27: Identifying Alignment Of All Timing Marks
    G04627533Courtesy of FORD MOTOR CO.
  30. Install the crankshaft sensor ring on the crankshaft.
    Fig 28: View Of Crankshaft Sensor Ring At Crankshaft
    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:
    1. 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.
    2. Make sure that the engine front cover gasket is in place on the engine front cover before installation.
    Fig 30: Identifying Silicone Gasket Silicone Gasket & Sealant To Cylinder Head-To-Cylinder Block Surface
    G04627536Courtesy 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 in Fig 30.
  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: Identifying Engine Front Cover And Alignment Dowels
    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 N.m (18 lb-ft).

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

    Fig 32: Identifying Tightening Sequence Of Engine Front Cover Bolts
    G04627538Courtesy 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 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: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
    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.
  38. Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown in Fig 35.
    • Tighten to 10 N.m (89 lb-in).
      Fig 35: Identifying Tightening Sequence Of Valve Cover Bolts
      G03919864Courtesy of FORD MOTOR CO.
    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: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
    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.
  41. Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown in Fig 37.
    • Tighten to 10 N.m (89 lb-in).
      Fig 37: Identifying Tighten Sequence Of Valve Cover Bolts
      G03919871Courtesy of FORD MOTOR CO.
  42. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 38: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  43. Using the special tools, install a new crankshaft front seal into the engine front cover.
    Fig 39: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    44. 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 40: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  44. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  45. Using the special tool, install the crankshaft pulley.
    Fig 41: Using Special Tool To Install Crankshaft Pulley
    G03920552Courtesy of FORD MOTOR CO.
  46. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
      Fig 42: Locating Crankshaft Pulley Bolt
      G04672695Courtesy of FORD MOTOR CO.
    47. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  47. Install the LH camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 43: Locating Bolt And LH CMP Sensor
      G03919989Courtesy of FORD MOTOR CO.
    48. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  48. Install the RH CMP sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 44: Locating Camshaft (CMP) Sensor Bolt
      G03920013Courtesy of FORD MOTOR CO.
  49. Position the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 45: Locating Crankshaft Position (CKP) Sensor Bolt
      G03920231Courtesy of FORD MOTOR CO.
  50. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 46: Identifying Accessory Drive Belt Tensioner Bolts
      G03920234Courtesy of FORD MOTOR CO.
  51. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 47: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts
      G03933688Courtesy of FORD MOTOR CO.
  52. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
    53. NOTE: LH shown, RH similar.
  53. Install the 8 ignition coils and the 8 bolts.
    • Tighten to 6 N.m (53 lb-in).
      Fig 48: Identifying Ignition Coils And Bolts
      G03920226Courtesy of FORD MOTOR CO.
  54. Install the LH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 49: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
      G03920225Courtesy of FORD MOTOR CO.
  55. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 50: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  56. Connect the 4 RH ignition coil electrical connectors.
    Fig 51: Locating Ignition Coil Electrical Connectors
    G03920223Courtesy of FORD MOTOR CO.
  57. Connect the electrical connector retainer to the coolant tube.
    Fig 52: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  58. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 53: Locating Engine Wiring Harness Retainers At RH Valve Cover
    G03920221Courtesy of FORD MOTOR CO.
  59. Connect the RH VCT solenoid electrical connector.
    Fig 54: Locating Camshaft Timing (VCT) Solenoid Electrical Connectors
    G03920220Courtesy of FORD MOTOR CO.
  60. Install the RH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 55: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
      G03920219Courtesy of FORD MOTOR CO.
  61. Connect the RH CMP sensor electrical connector.
    Fig 56: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  62. Using a suitable floor crane, remove the engine from the engine stand.
  63. 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 N.m (89 lb-in).
      Fig 57: Locating Oil Level Indicator Tube & Bolt
      G04627563Courtesy of FORD MOTOR CO.
  64. Position the RH engine support insulator and install the 3 bolts.
    • Tighten to 63 N.m (46 lb-ft).
      Fig 58: Identifying RH Engine Support Insulator Bolts
      G03933620Courtesy of FORD MOTOR CO.
  65. Install the flexplate and the 8 bolts in the sequence shown in Fig 59.
    • Tighten to 80 N.m (59 lb-ft).
      Fig 59: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts
      G03920141Courtesy of FORD MOTOR CO.
  66. Install the engine. For additional information, refer to ENGINE  .
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