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Cylinder Head: Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION:
    1. 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.
    2. 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.
    4. 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.
  2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
  3. Inspect the cylinder head for distortion. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  4. Apply silicone gasket and sealant to the locations shown.
    Fig 1: Identifying Silicone Gasket And Sealant Location
    G03897827Courtesy of FORD MOTOR CO.
  5. Install a new cylinder head gasket.
    6. NOTE:
    1. The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    2. Lubricate the bolts with clean engine oil prior to installation.
  6. Install new cylinder head bolts. Tighten the bolts in the sequence shown in the following 5 stages:
    • Stage 1: Tighten to 5 N.m (44 lb-in).
    • Stage 2: Tighten to 15 N.m (11 lb-ft).
    • Stage 3: Tighten to 45 N.m (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
      Fig 2: Identifying Tightening Sequence Of Cylinder Head Bolts
      G04619004Courtesy of FORD MOTOR CO.
  7. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
  8. Connect the radio ignition interference capacitor electrical connector.
  9. Connect the EGR valve electrical connector.
  10. Install the catalytic converter. For additional information, refer to INSTALLATION .
  11. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
    12. NOTE: Lubricate the valve tappets with clean engine oil.
    Fig 3: Locating Valve Tappets
    G04619005Courtesy of FORD MOTOR CO.
  12. Install the valve tappets in their original positions.
    13. CAUTION: Install the camshafts with the alignment notches in the camshafts lined up so the camshaft alignment plate can be installed. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Failure to follow this procedure can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  13. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages.
    • Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until finger tight.
    • Stage 2: Tighten the bolts to 7 N.m (62 lb-in).
    • Stage 3: Tighten the bolts to 16 N.m (12 lb-ft).
      Fig 4: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
      G03897808Courtesy of FORD MOTOR CO.
  14. Install the special tool.
    Fig 5: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  15. Install the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS .
  16. Fill and bleed the engine cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
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