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Cylinder Head: Installation

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.

    Both cylinder heads 

    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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
  2. Apply metal surface prep, following package directions, to remove any traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  3. Inspect the cylinder head for distortion. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    4. 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 and cannot be reused.
    NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.
  4. Position a new cylinder head gasket and the cylinder head.
    5. CAUTION: Always use new bolts.
    NOTE: Lubricate the bolts with clean engine oil prior to installation.
    Fig 1: Installing New Bolts
    G03962056Courtesy of FORD MOTOR CO.
  5. Install the new bolts. Make sure the bolts are installed in the correct locations
    1. Install the new long bolts.
    2. Install the new short bolts.
  6. Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 40 Nm (30 lb-ft).
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    Fig 2: Tightening Bolts In Sequence
    G03962057Courtesy of FORD MOTOR CO.
    7. CAUTION: Each bolt must be loosened and the final tightening carried out prior to working on the next bolt in the sequence. Do not loosen all of the bolts at one time.
    Fig 3: Identifying Final Tightening Sequence Of Bolts
    G03962057Courtesy of FORD MOTOR CO.
  7. Carry out the following final tightening process on each bolt in the sequence shown.
    • Long bolts:
      • Loosen and back out 3 turns.
      • Tighten to 45 Nm (33 lb-ft).
      • Tighten an additional 180 degrees.
      • Continue on to the next bolt in the sequence.
    • Short bolts
      • Loosen and back out 3 turns.
      • Tighten to 25 Nm (18 lb-ft).
      • Tighten an additional 180 degrees.
      • Continue on to the next bolt in the sequence.
  8. Install the exhaust manifold lower studs.
    • Tighten to 8 Nm (71 lb-in).
    Fig 4: Installing Exhaust Manifold Lower Studs
    G03962055Courtesy of FORD MOTOR CO.

    9. LH cylinder head 

  9. Install the push rods in the LH cylinder head. For additional information, refer to PUSH ROD .
  10. Connect the KS and CHT electrical connectors. Attach the HO2S electrical connector to the rear of the LH cylinder head.
  11. Install the LH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD - LH .
  12. Position back the A/C compressor and power steering bracket and loosely install the bolt.
  13. Position back the A/C compressor and power steering bracket brace and install the 2 bolts. Tighten the 3 bolts.
    • Tighten to 48 Nm (35 lb-ft).
  14. Install the nuts for the A/C compressor and power steering bracket brace.
    • Tighten to 25 Nm (18 lb-ft).
  15. If equipped, install the A/C compressor. For additional information, refer to AIR CONDITIONING .

    16. RH cylinder head 

  16. Install the push rods in the RH cylinder head. For additional information, refer to PUSH ROD .
  17. Attach the HO2S electrical connector retainer to the rear of the RH cylinder head. Position the ground wire and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
  18. Install the RH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD - RH .
  19. Position the radio interference capacitor and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
  20. Position the generator bracket, the generator, the accessory drive belt tensioner and the accessory drive belt idler pulley as an assembly and install the 3 bolts.
    • Tighten to 48 Nm (35 lb-ft).
  21. Position the upper idler pulley and install the bolt.
    • Tighten the bolt to 55 Nm (41 lb-ft).

    22. Both cylinder heads 

  22. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
    Fig 5: Installing Accessory Drive Belt
    G03962054Courtesy of FORD MOTOR CO.
  23. Install the lower intake manifold. For additional information, refer to LOWER INTAKE MANIFOLD .
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