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Cylinder Head: Assembly

All cylinder heads 

  1. Install the valve.
    GFD883381Courtesy of FORD MOTOR COMPANY
  2. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.

    Using the special tool, install the valve stem seal. Refer to: Specifications . Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal.

    GFD883382Courtesy of FORD MOTOR COMPANY
  3. Using the special tools, install the valve spring, valve spring retainer and the valve collet. Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor., 303-350 (T89P-6565-A) Compressor, Valve Spring., 303-1249 Valve Spring Compressor., 303-1418 Compressor, Valve Spring.
    GFD883378Courtesy of FORD MOTOR COMPANY
  4. Repeat the previous 3 steps for each valve.
  5. Install the spark plugs.

    Torque: 15 Nm

    GFD883377Courtesy of FORD MOTOR COMPANY

    RH cylinder head 

  6. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    1. Install the Arbor on the fuel injector tips. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
    2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
      NOTE: Make sure that new lower fuel injector Teflon® seals are installed.

      Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor.

    3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

    GFD883383Courtesy of FORD MOTOR COMPANY
  7. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
    NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

    1. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
    2. Position the Teflon® Seal Sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® Seal Sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
    3. Once the Teflon® Seal Sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® Seal Sizer tool. After one minute, turn the Teflon® Seal Sizer tool back 180 degrees and remove.
    4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.

    GFD883384Courtesy of FORD MOTOR COMPANY
    1. NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

      Install the fuel injector backup ring.

    2. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
      NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

      Install the new fuel injector O-ring seals. Lubricate the new fuel injector O-ring seals with clean engine oil. Refer to: Specifications .

    3. Install the new the fuel injector retaining clip.
    GFD883385Courtesy of FORD MOTOR COMPANY
  9. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD883386Courtesy of FORD MOTOR COMPANY
  10. Connect the fuel injector electrical connectors.
    GFD883264Courtesy of FORD MOTOR COMPANY
  11. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and direct injection fuel rail assembly into the cylinder head. Tighten the bolts in sequence shown below in 2 stages.

      Torque: Stage 1: 10 Nm Stage 2: 45deg.

    Fig 1: Direct Injection Fuel Rail Assembly to Cylinder Head Tightening Sequence
    GFD883387Courtesy of FORD MOTOR COMPANY
  12. NOTE: Install short end of stud into cylinder head assembly.

    • Loosely install the new studs into the cylinder head.

    • Tighten the studs.

      Torque: 13 Nm

    • Install the new exhaust manifold gasket.

    GFD883388Courtesy of FORD MOTOR COMPANY
  13. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown below in 2 stages.

    Torque: Stage 1: 16 Nm Stage 2: 22 Nm

    Fig 2: Exhaust Manifold Tightening Sequence
    GFD883389Courtesy of FORD MOTOR COMPANY
  14. Install the EGR to exhaust manifold connector.

    Torque: 170 Nm

    GFD883371Courtesy of FORD MOTOR COMPANY

    LH cylinder head 

  15. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    1. Install the Arbor on the fuel injector tips. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
    2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
      NOTE: Make sure that new lower fuel injector Teflon® seals are installed.

      Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor.

    3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

    GFD883383Courtesy of FORD MOTOR COMPANY
  16. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
    NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

    1. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
    2. Position the Teflon® Seal Sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® Seal Sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
    3. Once the Teflon® Seal Sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® Seal Sizer tool. After one minute, turn the Teflon® Seal Sizer tool back 180 degrees and remove.
    4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.

    GFD883384Courtesy of FORD MOTOR COMPANY
    1. NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

      Install the fuel injector backup ring.

    2. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
      NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

      Install the new fuel injector O-ring seals. Lubricate the new fuel injector O-ring seals with clean engine oil. Refer to: Specifications .

    3. Install the new the fuel injector retaining clip.
    GFD883385Courtesy of FORD MOTOR COMPANY
  18. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD883390Courtesy of FORD MOTOR COMPANY
  19. Connect the fuel injector electrical connectors.
    GFD883256Courtesy of FORD MOTOR COMPANY
  20. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and direct injection fuel rail assembly into the cylinder head. Tighten the bolts in sequence shown below in 2 stages.

      Torque: Stage 1: 10 Nm Stage 2: 45deg.

    • Connect the fuel injector electrical connectors.

    Fig 3: Direct Injection Fuel Rail Assembly to Cylinder Head Tightening Sequence
    GFD883391Courtesy of FORD MOTOR COMPANY
  21. NOTE: Install short end of stud into cylinder head assembly.

    • Loosely install the new studs into the cylinder head.

    • Tighten the studs.

      Torque: 13 Nm

    • Install the new exhaust manifold gasket.

    GFD883392Courtesy of FORD MOTOR COMPANY
  22. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown below in 2 stages.

    Torque: Stage 1: 16 Nm Stage 2: 22 Nm

Fig 4: Exhaust Manifold Tightening Sequence
GFD883393Courtesy of FORD MOTOR COMPANY
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