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Home >> Audi >> 2016 >> S5 Prestige, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 1072 (Engine - 3.5L ECOBOOST (272KW/370PS)) >> Disassembly And Assembly Of Subassemblies >> Cylinder Head >> Assembly

Cylinder Head: Assembly

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All cylinder heads 

  1. Install the valve.
    GFD272766Courtesy 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.Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal.

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    GFD272767Courtesy 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.
    GFD272763Courtesy of FORD MOTOR COMPANY
  4. Repeat the previous 3 steps for each valve.
  5. Install the spark plugs.

    Torque: 133 lb.in (15 Nm)

    GFD272762Courtesy 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.

    GFD272768Courtesy 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.

    GFD272769Courtesy 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.

      Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    3. Install the new the fuel injector retaining clip.
    GFD272770Courtesy 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.

    GFD272771Courtesy of FORD MOTOR COMPANY
  10. 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 in 2 stages.

      Torque:

      Stage 1: 89 lb.in (10 Nm)

      Stage 2: 45°

    • Connect the fuel injector electrical connectors.

    GFD272772Courtesy of FORD MOTOR COMPANY
  11. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not interchangeable.
    NOTE: Make sure that new fuel injector O-ring seals are installed.

    Install the new fuel injector O-ring seals and the fuel injector retaining clips onto the fuel injectors. Lubricate the new fuel injector O-ring seals with clean engine oil.

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    GFD272773Courtesy of FORD MOTOR COMPANY
  12. 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.

    GFD272774Courtesy of FORD MOTOR COMPANY
  13. 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 port injection fuel rail assembly into the cylinder head and tighten the bolts.

      Torque: 89 lb.in (10 Nm)

    • Connect the fuel injector electrical connectors.

    GFD272775Courtesy of FORD MOTOR COMPANY
  14. NOTE: Install short end of stud into cylinder head assembly.

    • Loosely install the new studs into the cylinder head.

    • Tighten the studs in sequence shown.

      Torque: 159 lb.in (18 Nm)

    • Install the new exhaust manifold gasket.

    GFD272776Courtesy of FORD MOTOR COMPANY
  15. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown in 2 stages.

    Torque:

    Stage 1: 168 lb.in (19 Nm)

    Stage 2: 18 lb.ft (25 Nm)

    GFD272777Courtesy of FORD MOTOR COMPANY
  16. Install the new CHT sensor.

    Torque: 97 lb.in (11 Nm)

    GFD272778Courtesy of FORD MOTOR COMPANY
  17. Install Special Service Tool: 303-1654 Lift Eyes.

    Torque: 18 lb.ft (25 Nm)

    GFD272750Courtesy of FORD MOTOR COMPANY

    LH cylinder head 

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

    1. Install the Arbor on the fuel injector tipsUse 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.

    GFD272768Courtesy of FORD MOTOR COMPANY
  19. 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.

    GFD272769Courtesy 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.

      Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    3. Install the new the fuel injector retaining clip.
    GFD272770Courtesy of FORD MOTOR COMPANY
  21. 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.

    GFD272779Courtesy of FORD MOTOR COMPANY
  22. 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 in 2 stages.

      Torque:Stage 1: 89 lb.in (10 Nm)Stage 2: 45°

    • Connect the fuel injector electrical connectors.

    GFD272780Courtesy of FORD MOTOR COMPANY
  23. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not interchangeable.
    NOTE: Make sure that new fuel injector O-ring seals are installed.

    Install the new fuel injector O-ring seals and the fuel injector retaining clips onto the fuel injectors. Lubricate the new fuel injector O-ring seals with clean engine oil.

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    GFD272773Courtesy of FORD MOTOR COMPANY
  24. 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.

    GFD272781Courtesy of FORD MOTOR COMPANY
  25. 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 port injection fuel rail assembly into the cylinder head and tighten the bolts.

      Torque: 89 lb.in (10 Nm)

    • Connect the fuel injector electrical connectors.

    GFD272782Courtesy of FORD MOTOR COMPANY
  26. NOTE: Install short end of stud into cylinder head assembly.

    • Loosely install the new studs into the cylinder head.

    • Tighten the studs in sequence shown.

      Torque: 159 lb.in (18 Nm)

    • Install the new exhaust manifold gasket.

    GFD272783Courtesy of FORD MOTOR COMPANY
  27. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown in 2 stages.

    Torque:

    Stage 1: 168 lb.in (19 Nm)

    Stage 2: 18 lb.ft (25 Nm)

    GFD272784Courtesy of FORD MOTOR COMPANY
  28. Install Special Service Tool: 303-1654 Lift Eyes.

    Torque: 18 lb.ft (25 Nm)

GFD272736Courtesy of FORD MOTOR COMPANY
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