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Cylinder Head: Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

    Both sides 

  1. Clean the cylinder head bolts in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
  2. Position the cylinder head gasket on the block.
    Fig 1: Positioning Cylinder Head Gasket On Block
    G03983805Courtesy of FORD MOTOR CO.

    3. RH side 

    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.
  3. 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: Tightening Cylinder Head Bolts In Sequence
      G03946980Courtesy of FORD MOTOR CO.
  4. Install 2 new 8-mm (0.32 in) head bolts.
    • Tighten to 32 Nm (24 lb-ft).
      Fig 3: Installing Bolts
      G03946981Courtesy of FORD MOTOR CO.
  5. Tighten the 8 12-mm bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten the bolts 90 degrees.
    • Stage 2: Tighten the bolts an additional 90 degrees.
      Fig 4: Tightening Bolts In Sequence
      G03946980Courtesy of FORD MOTOR CO.
    6. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time
    Fig 5: Installing Camshaft Sprocket And Bolt
    G03947061Courtesy of FORD MOTOR CO.
  6. Remove the rubber band. Install the camshaft sprocket and bolt.
  7. Install the RH side cassette bolt.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 6: Installing RH Side Cassette Bolt
      G03983797Courtesy of FORD MOTOR CO.

    8. LH side 

    CAUTION: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head ii the vehicle.
    NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
  8. Install the cylinder head. Install 8 new 12-mm 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 7: Installing 12-MM Bolts And Tightening In Sequence
      G03946985Courtesy of FORD MOTOR CO.
  9. Install 2 new 8-mm bolts.
    • Tighten to 32 Nm (24 lb-ft).
      Fig 8: Installing 8-MM Bolts
      G03946981Courtesy of FORD MOTOR CO.
  10. Tighten the 8 12-mm bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten the bolts 90 degrees.
    • Stage 2: Tighten the bolts an additional 90 degrees.
      Fig 9: Tightening 12-MM Bolts In Sequence
      G03946985Courtesy of FORD MOTOR CO.
    11. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.
    Fig 10: Identifying LH Camshaft Sprocket Bolt
    G03913892Courtesy of FORD MOTOR CO.
  11. Remove the rubber band. Install the camshaft sprocket and bolt.
  12. Install the LH side cassette bolt.
    • Tighten to 19 Nm (14 lb-ft).
      Fig 11: Identifying LH Cassette Upper Bolt
      G03913945Courtesy of FORD MOTOR CO.

    13. Both sides 

  13. Install both of the exhaust manifolds gaskets, the exhaust manifolds and the nuts.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 12: Installing Both Of Exhaust Manifolds Gaskets, Exhaust Manifolds And Nuts
      G03946967Courtesy of FORD MOTOR CO.
    14. NOTE: Apply dielectric compound to the inside of the spark plug wire boots.
    Fig 13: Connecting Spark Plug Wires To Spark Plugs
    G03946991Courtesy of FORD MOTOR CO.
  14. Connect all of the spark plug wires to the spark plugs.
    15. NOTE: LH side shown, RH side similar.
  15. Install the 4 catalytic converter-to-exhaust manifold nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 14: Locating Catalytic Converter-To-Manifold Nuts
      G03946966Courtesy of FORD MOTOR CO.
  16. Install the engine noise shield.
    Fig 15: Installing Engine Noise Shield
    G03946993Courtesy of FORD MOTOR CO.

    17. RH side 

  17. Install the engine ground strap and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 16: Installing Engine Ground Strap And Bolt
      G03946958Courtesy of FORD MOTOR CO.
  18. Position the engine wiring harness and install the bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 17: Positioning Engine Wiring Harness
      G03946995Courtesy of FORD MOTOR CO.
    19. NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary.
  19. Install the thermostat housing and the bolts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 18: Installing Thermostat Housing And Bolts
      G03946956Courtesy of FORD MOTOR CO.
  20. Position the coolant bypass hose clamp.
    Fig 19: Positioning Coolant Bypass Hose Clamp
    G03983779Courtesy of FORD MOTOR CO.
  21. Install the upper radiator hose.
    Fig 20: Installing Upper Radiator Hose
    G03914437Courtesy of FORD MOTOR CO.
  22. Connect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 21: Connecting Engine Coolant Temperature Sensor Electrical Connector
    G03946953Courtesy of FORD MOTOR CO.
  23. Install the heater hose to the thermostat housing.
    Fig 22: Installing Heater Hose To Thermostat Housing
    G03946952Courtesy of FORD MOTOR CO.
  24. Install the generator mounting bracket assembly and the bolts.
    • Tighten to 42 Nm (31 lb-ft).
      Fig 23: Installing Generator Mounting Bracket Assembly And Bolts
      G03947001Courtesy of FORD MOTOR CO.
  25. Connect the generator electrical connections and install the pushpin.
    • Tighten to 8 Nm (71 lb-in).
      Fig 24: Connecting Generator Electrical Connections
      G03946950Courtesy of FORD MOTOR CO.

    26. LH side 

  26. Install the oil level indicator tube and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 25: Locating Bolt And Oil Level Indicator Tube
      G03913929Courtesy of FORD MOTOR CO.
  27. Install the coil bracket and the bolts.
    • Tighten to 89 Nm (10 lb-in).
      Fig 26: Installing Coil Bracket And Bolts
      G03947447Courtesy of FORD MOTOR CO.
  28. Install the accessory bracket and the bolts.
    • Tighten to 42 Nm (31 lb-ft).
      Fig 27: Identifying Accessory Bracket Bolts And Bracket
      G03913802Courtesy of FORD MOTOR CO.
  29. Install the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Installing Bolts
      G03946960Courtesy of FORD MOTOR CO.
  30. Connect the radio ignition interference capacitor electrical connector.
    Fig 29: Connecting Radio Ignition Interference Capacitor Electrical Connector
    G03946959Courtesy of FORD MOTOR CO.

    31. Both sides 

  31. Install the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE .
    32. NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed.
  32. Turn the crankshaft clockwise to position the number one cylinder at top dead center (TDC).
  33. Remove the retainer and position the A/C manifold tube bracket aside.
    Fig 30: Positioning A/C Manifold Tube Bracket Aside
    G03947020Courtesy of FORD MOTOR CO.
    34. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.
    NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
    Fig 31: Installing Special Tool
    G03946899Courtesy of FORD MOTOR CO.
  34. Install the special tool.
    35. NOTE: Leave the top 2 special tool clamp bolts loose.
    Fig 32: Installing Special Tools On Rear Of RH Cylinder Head
    G03946900Courtesy of FORD MOTOR CO.
  35. Install the special tools on the rear of the RH cylinder head.
    36. NOTE: The camshaft timing slots are off-center.
    Fig 33: Installing Special Tools On Front Of RH Cylinder Head
    G03946903Courtesy of FORD MOTOR CO.
  36. 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.
  37. Install the special tool.
    Fig 34: Installing Special Tool
    G03946905Courtesy of FORD MOTOR CO.
    38. CAUTION: The RH camshaft sprocket bolt is a LH threaded bolt.
  38. 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.
      • Tighten to 61 Nm (45 lb-ft).
        Fig 35: Tightening Camshaft Bolt Using Special Tool
        G03946906Courtesy of FORD MOTOR CO.
  39. Install the RH camshaft tensioner.
    • Tighten to 44 Nm (32 lb-ft).
      Fig 36: Installing RH Camshaft Tensioner
      G03947014Courtesy of FORD MOTOR CO.
    40. NOTE: Leave the top 2 special tool clamp bolts loose.
    Fig 37: Identifying Special Holding Tool
    G03946909Courtesy of FORD MOTOR CO.
  40. Install the special tools on the front of the LH cylinder head.
    41. NOTE: The camshaft timing slots are off-center.
    Fig 38: Installing Special Tools On Rear Of LH Cylinder Head
    G03946903Courtesy of FORD MOTOR CO.
  41. 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.
  42. Install the special tool.
    Fig 39: Installing Special Tool
    G03946914Courtesy of FORD MOTOR CO.
  43. Tighten the bolts.
    1. Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in).
    2. Tighten the camshaft bolt.
      • Tighten to 85 Nm (63 lb-ft).
        Fig 40: Tightening Camshaft Bolt
        G03947018Courtesy of FORD MOTOR CO.
  44. Install the LH camshaft tensioner.
    • Tighten to 44 Nm (32 lb-ft).
      Fig 41: Identifying LH Camshaft Tensioner
      G03913851Courtesy of FORD MOTOR CO.
  45. Install the A/C manifold tube assembly bracket and the nut.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 42: Installing A/C Manifold Tube Assembly Bracket And Nut
      G03947020Courtesy of FORD MOTOR CO.
  46. Install the roller followers. For additional information, refer to CAMSHAFT ROLLER FOLLOWER .
  47. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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