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Cylinder Head: Installation

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

    Both sides 

  1. Position the cylinder head gasket on the block.
    Fig 1: Positioning Cylinder Head Gasket On Block
    G03180507Courtesy of FORD MOTOR CO.
    2. CAUTION: To avoid damage to the timing chain cassette an assistant will be required to help position the cylinder head in the vehicle.
    CAUTION: On the RH side, when lifting the cylinder head, be careful to avoid contacting the A/C tube or the A/C tube can be damaged.
    NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
  2. Install the cylinder head. Install new 12 mm (0.48 in) bolts and tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten to 12 Nm (9 lb-ft).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
      Fig 2: Identifying Tightening Sequence Of Cylinder Head Bolts
      G04638041Courtesy of FORD MOTOR CO.
  3. Install two new 8 mm (0.32 in) head bolts.
    Fig 3: Installing Two New 8 Mm (0.32 In) Head Bolts
    G03180509Courtesy of FORD MOTOR CO.
  4. Tighten the eight 12 mm (0.48 in) bolts in the sequence shown in two stages.
    • Tighten the bolts 90 degrees.
    • Tighten the bolts an additional 90 degrees.
    Fig 4: Tightening Bolts An Additional 90 Degrees In Sequence
    G03180510Courtesy of FORD MOTOR CO.

    5. RH side 

    CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time
    Fig 5: Installing Camshaft Sprocket
    G03180511Courtesy of FORD MOTOR CO.
  5. Remove the rubber band. Install the camshaft sprocket and bolt.
  6. Install the RH side cassette bolt.
    Fig 6: Installing RH Side Cassette Bolt
    G03180512Courtesy of FORD MOTOR CO.

    7. LH side 

    CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.
    Fig 7: Installing Camshaft Sprocket
    G03180513Courtesy of FORD MOTOR CO.
  7. Remove the rubber band. Install the camshaft sprocket and bolt.
  8. Install the LH side cassette bolt.
    Fig 8: Installing LH Side Cassette
    G03180514Courtesy of FORD MOTOR CO.

    9. Both sides 

  9. Install both of the exhaust manifolds and gaskets.
    Fig 9: Installing Both Exhaust Manifolds And Gaskets
    G03180515Courtesy of FORD MOTOR CO.
    10. NOTE: Apply dielectric compound to the inside of the spark plug wire boots.
    Fig 10: Connecting All Spark Plug Wires To Spark Plugs
    G03180516Courtesy of FORD MOTOR CO.
  10. Connect all of the spark plug wires to the spark plugs.
    11. NOTE: LH side shown, RH side similar.
    Fig 11: Installing Catalytic Converter-To-Exhaust Manifold Nuts
    G03180517Courtesy of FORD MOTOR CO.
  11. Install the four catalytic converter-to-exhaust manifold nuts.
  12. Install the engine noise shield.
    Fig 12: Installing Engine Noise Shield
    G03180518Courtesy of FORD MOTOR CO.

    13. RH side 

  13. Install the engine ground strap.
    Fig 13: Installing Engine Ground Strap
    G03180519Courtesy of FORD MOTOR CO.
  14. Position the engine wiring harness and install the bolts.
    Fig 14: Positioning Engine Wiring Harness
    G03180520Courtesy of FORD MOTOR CO.
    15. NOTE: Inspect the O-ring. Install a new O-ring if necessary.
    Fig 15: Installing Thermostat Housing
    G03180521Courtesy of FORD MOTOR CO.
  15. Install the thermostat housing.
  16. Position the coolant bypass hose clamp.
    Fig 16: Positioning Coolant Bypass Hose Clamp
    G03180522Courtesy of FORD MOTOR CO.
  17. Install the upper radiator hose.
    Fig 17: Installing Upper Radiator Hose
    G03180523Courtesy of FORD MOTOR CO.
  18. Connect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 18: Connecting Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03180524Courtesy of FORD MOTOR CO.
  19. Install the heater hose to the thermostat housing.
    Fig 19: Installing Heater Hose To Thermostat Housing
    G03180525Courtesy of FORD MOTOR CO.
  20. Install the generator mounting bracket assembly.
    Fig 20: Installing Generator Mounting Bracket Assembly
    G03180526Courtesy of FORD MOTOR CO.
  21. Install the accessory drive belt tensioner.
    Fig 21: Installing Accessory Drive Belt Tensioner
    G03180527Courtesy of FORD MOTOR CO.
  22. Connect the generator electrical connections and install the pushpin.
    Fig 22: Connecting Generator Electrical Connections And Install Pushpin
    G03180528Courtesy of FORD MOTOR CO.

    23. LH side 

  23. Install the oil level indicator tube and bolt.
    Fig 23: Installing Oil Level Indicator Tube And Bolt
    G03180529Courtesy of FORD MOTOR CO.
  24. Install the coil bracket and the bolts.
    Fig 24: Installing Coil Bracket And Bolts
    G03180530Courtesy of FORD MOTOR CO.
  25. Install the accessory bracket.
    Fig 25: Installing Accessory Bracket
    G03180531Courtesy of FORD MOTOR CO.
  26. Install the bolts.
    Fig 26: Installing Bolts
    G03180532Courtesy of FORD MOTOR CO.
  27. Connect the radio ignition interference capacitor electrical connector.
    Fig 27: Connecting Radio Ignition Interference Capacitor Electrical Connector
    G03180533Courtesy of FORD MOTOR CO.

    28. Both sides 

  28. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE BELT, TENSIONER AND PULLEY .
    29. NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed.
  29. Turn the crankshaft clockwise to position the number one cylinder at top dead center (TDC).
  30. Remove the retainer and position the A/C manifold tube bracket aside.
    Fig 28: Removing Retainer And Position A/C Manifold Tube Bracket
    G03180534Courtesy of FORD MOTOR CO.
    31. NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
    NOTE: Late build pulley shown, early build pulley similar.
    Fig 29: Installing Special Tool
    G03180535Courtesy of FORD MOTOR CO.
  31. Install the special tool.
    32. NOTE: Leave the top two special tool clamp bolts loose.
    Fig 30: Installing Special Tools On Rear Of RH Cylinder Head
    G03180536Courtesy of FORD MOTOR CO.
  32. Install the special tools on the rear of the RH cylinder head.
    33. NOTE: The camshaft timing slots are off-center.
    Fig 31: Installing Special Tools On Front Of RH Cylinder Head
    G03180537Courtesy of FORD MOTOR CO.
  33. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the front of the RH cylinder head.
  34. Install the special tool.
    Fig 32: Installing Special Tool
    G03180538Courtesy of FORD MOTOR CO.
    35. CAUTION: The RH camshaft sprocket bolt is a LH threaded bolt.
    Fig 33: Tightening Camshaft Bolt
    G03180539Courtesy of FORD MOTOR CO.
  35. Tighten the bolts.
    1. Tighten the special tool top clamp bolts to 10 Nm (89 lb-in).
    2. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt.
  36. Install the RH camshaft tensioner.
    Fig 34: Installing RH Camshaft Tensioner
    G03180540Courtesy of FORD MOTOR CO.
    37. NOTE: Leave the top two special tool clamp bolts loose.
    Fig 35: Installing Special Tools On Front Of LH Cylinder Head
    G03180541Courtesy of FORD MOTOR CO.
  37. Install the special tools on the front of the LH cylinder head.
    38. NOTE: The camshaft timing slots are off-center.
    Fig 36: Positioning Camshaft Timing Slots Below Centerline Of Camshaft To Correctly Fit Special Tools
    G03180542Courtesy of FORD MOTOR CO.
  38. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head.
  39. Install the special tool.
    Fig 37: Installing Special Tool
    G03180543Courtesy of FORD MOTOR CO.
  40. Tighten the bolts.
    1. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in).
    2. Tighten the camshaft bolt.
    Fig 38: Tightening Camshaft Bolt
    G03180544Courtesy of FORD MOTOR CO.
  41. Install the LH camshaft tensioner.
    Fig 39: Installing LH Camshaft Tensioner
    G03180545Courtesy of FORD MOTOR CO.
  42. Install the A/C manifold tube assembly bracket.
    Fig 40: Installing A/C Manifold Tube Assembly Bracket
    G03180546Courtesy of FORD MOTOR CO.
  43. Install the roller followers. For additional information, refer to CAMSHAFT ROLLER FOLLOWER AND HYDRAULIC LASH ADJUSTER .
  44. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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