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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 972 (Engine - 4.6L (2V) - F150 Pickup) >> Installation >> Cylinder Head

Cylinder Head

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G03905862
 Installer, Connecting Rod 303-442 (T93P-6136-A)
G03919900
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
G03886827
 Installer, Crankshaft Front Seal 303-635
G03920628
 Installer, Crankshaft Front Seal 303-335 (T88T-6701-A)
G03920362
 Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
G03905601
 Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH)
G03886833
 Installer, Crankshaft Rear Slinger 303-517 (T95P-6701-CH)
G03885486
 Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH)
G03962472
 Compressor, Valve Spring 303-452 (T91P-6571-AH)
G03885376
 Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
G03886987
 Alignment Pins, Cylinder Head 303-1040
G03886455
 Holding Tool, Crankshaft 303-448 (T93P-6303-A)
G03886715
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
MATERIALS

Item Specification
Motorcraft Metal Surface Prep ZC-31 -
Silicone Gasket Remover ZC-30 -
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Instant Gel Adhesive TA-19 WSK-M2G402-A4
Threadlock 262 TA-26 WSK-M2G351-A6
Motorcraft SAE 5W-20 Premium Synthetic Blend Engine 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
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA -

    All cylinder heads 

    CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    NOTE: Do not turn the crankshaft until instructed to do so.
    Fig 1: Using Special Tools To Position Cylinder Head Gaskets And Cylinder Heads Over Dowels And Installing Cylinder Head Bolts Loosely
    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.
    • LH shown, RH similar.

    2. LH cylinder head 

    NOTE: Make sure to tighten the bolts in sequence in 3 stages.
    Fig 2: Identifying Tightening Sequence Of LH cylinder Head Bolts
    G03962790Courtesy of FORD MOTOR CO.
  2. Tighten the LH bolts in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.

    3. RH cylinder head 

    NOTE: Make sure to tighten the bolts in the following 3 stages.
    Fig 3: Identifying Tightening Sequence Of RH Cylinder Head Bolts
    G03962906Courtesy of FORD MOTOR CO.
  3. Tighten the RH bolts in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.

    4. All cylinder heads 

    CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    CAUTION: 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 4: Compressing Tensioner Plunger Using Vise
    G03885344Courtesy of FORD MOTOR CO.
  4. Compress the tensioner plunger, using a vise.
  5. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 5: Installing Retaining Clip On Tensioner
    G03881580Courtesy of FORD MOTOR CO.
  6. Remove the tensioner from the vise.
  7. 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 6: Marking One Link On One End And One Link On The Other End And Using As Timing Marks
    G03881581Courtesy of FORD MOTOR CO.
  8. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 7: Installing Crankshaft Sprocket
    G03919967Courtesy of FORD MOTOR CO.
  9. 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.
      • Tighten to 10 Nm (89 lb-in).
    Fig 8: Installing Timing Chain Guides
    G03962457Courtesy of FORD MOTOR CO.
  10. 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 9: Identifying Timing Mark
    G04583473Courtesy of FORD MOTOR CO.
    11. NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
    Fig 10: Positioning Crankshaft So No. 1 Cylinder Is At TDC With Special Tool
    G03947638Courtesy of FORD MOTOR CO.
  11. Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.
  12. Remove the Crankshaft Holding Tool.
  13. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 11: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03962459Courtesy of FORD MOTOR CO.
  14. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 12: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03962460Courtesy of FORD MOTOR CO.
    15. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 13: Installing LH Timing Chain Tensioner
    G03962803Courtesy of FORD MOTOR CO.
  15. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
  16. Remove the retaining clip from the LH timing chain tensioner.
    Fig 14: Removing Retaining Clip From LH Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  17. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 15: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03948189Courtesy of FORD MOTOR CO.
  18. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 16: Aligning Copper (Marked) Link With Timing Marks On Camshaft Sprocket
    G03885941Courtesy of FORD MOTOR CO.
  19. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 17: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
    G03962807Courtesy of FORD MOTOR CO.
  20. Remove the retaining clip from the RH timing chain tensioner.
    Fig 18: Removing Retaining Clip From RH Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  21. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    Fig 19: Identifying Camshaft & Crankshaft Alignment Links/Marks
    G03962922Courtesy of FORD MOTOR CO.
    22. NOTE: Camshaft roller follower is shown removed for clarity.
    Fig 20: Installing Special Tool Between Valve Spring Coils To Prevent Valve Stem Seal Damage
    G03962476Courtesy of FORD MOTOR CO.
  22. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    23. NOTE: The camshaft roller followers must be reinstalled in their original locations.
    NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.
    NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.
    Fig 21: Using Special Tool To Compress Valve Springs And Installing Camshaft Roller Follower
    G03962484Courtesy of FORD MOTOR CO.
  23. Use the special tool to compress the valve springs, and install the camshaft roller follower.
    24. NOTE: The camshaft roller followers must be reinstalled in their original locations.
    NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.
  24. Repeat the previous 3 steps for each of the camshaft roller followers.
  25. Install the crankshaft sensor ring on the crankshaft.
    Fig 22: Installing Crankshaft Sensor Ring On Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    26. 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: 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. 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.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
    Fig 23: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface
    G03886057Courtesy of FORD MOTOR CO.
  26. 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.
  27. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 24: Installing New Engine Front Cover Gasket On Engine Front Cover And Positioning Engine Front Cover
    G03881967Courtesy of FORD MOTOR CO.
  28. Tighten the engine front cover fasteners in the sequence shown.
    Fig 25: Identifying Tightening Sequence Of Engine Front Cover Fasteners
    G03962928Courtesy of FORD MOTOR CO.
  29. Install the camshaft position (CMP) sensor and the bolt.
    • Lubricate the O-ring seal with clean engine oil prior to installation.
    • Tighten to 10 Nm (89 lb-in).
    Fig 26: Installing Camshaft Position (CMP) Sensor And Bolt
    G03919989Courtesy of FORD MOTOR CO.
  30. Install the crankshaft position (CKP) sensor and the bolt.
    • Lubricate the O-ring seal with clean engine oil prior to installation.
    • Tighten to 10 Nm (89 lb-in).
    Fig 27: Installing Crankshaft Position (CKP) Sensor And Bolt
    G03920231Courtesy of FORD MOTOR CO.
  31. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 28: Lubricating Engine Front Cover And Crankshaft Front Seal Inner Lip With Clean Engine Oil
    G03881970Courtesy of FORD MOTOR CO.
  32. Use the special tools to install a new crankshaft front seal into the engine front cover.
    Fig 29: Using Special Tools To Install New Crankshaft Front Seal Into Engine Front Cover
    G03919891Courtesy of FORD MOTOR CO.
    33. 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 30: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03948080Courtesy of FORD MOTOR CO.
  33. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  34. Use the special tool to install the crankshaft pulley.
    Fig 31: Using Special Tool To Install Crankshaft Pulley
    G03919878Courtesy of FORD MOTOR CO.
  35. Tighten the new crankshaft pulley bolt in 4 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: Tighten an additional 90 degrees.
    Fig 32: Installing Crankshaft Pulley Bolt & Washer
    G04672695Courtesy of FORD MOTOR CO.
  36. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 33: Installing Accessory Drive Belt Idler Pulleys, Coolant Pump Pulley And Bolts
    G03933688Courtesy of FORD MOTOR CO.
  37. Position the accessory drive belt tensioner and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 34: Installing Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
    38. 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.
  38. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  39. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    Fig 35: Applying Instant Adhesive Completely Around Gasket Groove In RH Valve Cover
    G03905398Courtesy of FORD MOTOR CO.
    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 Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
    G03947588Courtesy of FORD MOTOR CO.
  40. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
  41. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 37: Installing Rh Valve Cover And Gasket On Cylinder Head
    G03905400Courtesy of FORD MOTOR CO.
  42. Tighten the valve cover bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    Fig 38: Identifying Tightening Sequence Of Valve Cover Bolts
    G03962378Courtesy of FORD MOTOR CO.
    43. 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.
  43. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  44. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    Fig 39: Applying Instant Adhesive Completely Around Gasket Groove In LH Valve Cover
    G03948210Courtesy of FORD MOTOR CO.
    45. 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 In 2 Places Where Engine Front Cover Meets Cylinder Head
    G03947580Courtesy of FORD MOTOR CO.
  45. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
  46. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 41: Installing LH Valve Cover And Gasket On Cylinder Head
    G03885960Courtesy of FORD MOTOR CO.
  47. Tighten the valve cover bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    Fig 42: Identifying Tightening Sequence Of Valve Cover Bolts
    G03962371Courtesy of FORD MOTOR CO.
    48. NOTE: RH shown, LH similar.
    Fig 43: Installing Radio Frequency Interference Capacitors
    G03906363Courtesy of FORD MOTOR CO.
  48. Install the radio frequency interference capacitors.
    • Tighten to 25 Nm (18 lb-ft).

    49. LH cylinder head 

    NOTE: Lubricate the O-ring seal with clean engine oil.
    Fig 44: Installing Oil Level Indicator Tube
    G03906387Courtesy of FORD MOTOR CO.
  49. Install the oil level indicator tube.
    • Install a new O-ring seal on the oil level indicator tube.
    • Install the oil level indicator tube.
    • Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
  50. Install the LH exhaust manifold and the exhaust manifold gasket. Tighten the nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 45: Identifying Tightening Sequence Of LH Exhaust Manifold Bolts
    G03962507Courtesy of FORD MOTOR CO.

    51. RH cylinder head 

  51. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 46: Identifying Tightening Sequence Of RH Exhaust Manifold Bolts
    G03962505Courtesy of FORD MOTOR CO.
  52. Slide the heater outlet tube forward with a new O-ring seal into the cylinder block.
    • Lubricate the O-ring seal with engine coolant.
    Fig 47: Sliding Heater Outlet Tube Forward With A New O-Ring Seal Into Cylinder Block
    G03885471Courtesy of FORD MOTOR CO.
  53. Install the heater outlet tube studs.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 48: Installing Heater Outlet Tube Studs
    G03962837Courtesy of FORD MOTOR CO.
  54. Connect the coolant hoses to the heater outlet tube.
    Fig 49: Connecting Coolant Hoses To Heater Outlet Tube
    G03962838Courtesy of FORD MOTOR CO.

    55. All cylinder heads 

  55. Position the electrical harness onto the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
  56. Connect the RH radio ignition interference capacitor electrical connector.
    Fig 50: Connecting RH Radio Ignition Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  57. Connect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 51: Connecting LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
  58. Position the upper radiator hose bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 52: Positioning Upper Radiator Hose Bracket And Installing Nut
    G03962421Courtesy of FORD MOTOR CO.
  59. Connect the CMP sensor electrical connectors.
    Fig 53: Connecting CMP Sensor Electrical Connectors
    G03885221Courtesy of FORD MOTOR CO.
  60. Connect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
    Fig 54: Connecting Knock Sensor (KS) Electrical Connector And Wiring Harness Pin-Type Retainer
    G03881828Courtesy of FORD MOTOR CO.
  61. Connect the engine oil pressure (EOP) sensor electrical connector.
    Fig 55: Connecting Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03962630Courtesy of FORD MOTOR CO.
  62. Connect the CKP sensor electrical connector.
    Fig 56: Connecting CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
    63. CAUTION: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
    Fig 57: Installing RH Engine Support Insulator Bolts
    G03933620Courtesy of FORD MOTOR CO.
  63. Position the RH engine support insulator and install the 3 bolts.
    • Apply Threadlock 262 to the bolt threads prior to installation.
    • Tighten to 63 Nm (46 lb-ft).
  64. Install the special tool.
    Fig 58: Installing Special Tool
    G03962845Courtesy of FORD MOTOR CO.
  65. Using a suitable floor crane, remove the engine from the engine stand.
  66. Install the spacer plate.
    Fig 59: Installing Spacer Plate
    G03947909Courtesy of FORD MOTOR CO.
  67. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
    Fig 60: Installing Tightening Sequence Of Flexplate Bolts
    G03947697Courtesy of FORD MOTOR CO.
  68. Install the engine. For additional information, refer to ENGINE .
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