Cylinder Head
WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) SPECIFICATIONS
| Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) |
|
| Holding Tool, Crankshaft 303-448 (T93P-6303-A) |
|
| Compressor, Valve Spring 303-1039 |
|
| Alignment Pins, Cylinder Head 303-1040 (SR-015486) |
|
| Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) |
|
| Installer, Crankshaft Front Seal 303-635 |
|
| Installer, Front Cover Seal 303-335 (T88T-6701-A) |
MATERIAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor 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 |
| Silicone Gasket and Sealant TA-30 or equivalent | WSE-M4G323-A4 |
| Motorcraft Metal Surface Prep ZC-31 | - |
| Silicone Gasket Remover ZC-30 | - |
| Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA | - |
- Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
- Tighten the 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.
- Install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).
- Install the RH engine mount and the bolts.
- Tighten to 63 Nm (46 lb-ft).
- Remove the special tool from the LH cylinder head.
- Install the hydraulic lash adjusters into the LH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
- Position a new gasket, the LH exhaust manifold and tighten the 10 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
- Remove the special tool from the RH cylinder head.
- Install the hydraulic lash adjusters into the RH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
- Position a new gasket, the RH exhaust manifold and tighten the 10 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
- Install the coolant tube and the stud bolt.
- Tighten to 10 Nm (89 lb-in).
- Install only the identified camshaft roller followers onto the RH cylinder head.
- Install only the identified camshaft roller followers onto the LH cylinder head.
- Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
- Install the LH and RH camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the front camshaft bearing cap.
- Position the remaining camshaft bearing caps.
- Install the bolts loosely.
- Tighten the LH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.
- Tighten the RH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.
- Install the balance shaft drive gear onto the LH camshaft.
- Install both camshaft sprockets and camshaft sprocket bolts finger tight.
- Compress the tensioner plunger, using a vise.
- Install a retaining clip on the tensioner to hold the plunger in during installation.
- If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
- Install the timing chain guides and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
- Preposition the camshafts.
- Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
- Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.
- Position the crankshaft with the special tool, then remove the tool.
- Install the crankshaft sprocket, marking sure the flange faces forward.
- Install the lower end of the LH timing chain, aligning the timing marks.
- Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
- Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
- Tighten to 25 Nm (18 lb-ft).
- Install the RH (outer) timing chain on the crankshaft sprocket.
- Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
- Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
- Tighten to 25 Nm (18 lb-ft).
- Remove the retaining clips from the RH and LH timing chain tensioners.
- Check for correct alignment of all timing marks.
- Install the crankshaft sensor ring on the crankshaft.
- Tighten the RH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft) in the sequence shown.
- Stage 2: Tighten an additional 90 degrees.
- Tighten the LH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft) in the sequence shown.
- Stage 2: Tighten an additional 90 degrees.
- Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
- Remove the 2 bolts and the camshaft bearing cap.
- Using the special tool, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.
- Position the camshaft bearing cap and install the bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
- Remove the 2 bolts and the camshaft bearing cap.
- Using the special tool, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.
- Position the camshaft bearing cap and install the bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.
- Using the special tool, install all of the remaining camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.
- Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
- Lubricate the balance shaft journals with clean engine oil.
- Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
- Position the balance shaft on the journals.
- Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.
- Install the bolts and tighten in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
- Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
- Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
- Tighten the engine front cover fasteners in sequence in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
COMPONENTS DESCRIPTION CHARTItem Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50 6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103 7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 11 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94 12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94 13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94 14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94 15 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 56 - Install the front 4 oil pan bolts in the sequence shown, in 2 stages:
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
- Install the camshaft position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
- Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
- Using the special tools, install a new crankshaft seal into the engine front cover.
- Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
- Use the special tool to install the crankshaft pulley.
- 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.
- Position the crankshaft position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
- Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
- Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
- Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
- Position the LH valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
- Position the oil level indicator and tube and install the bolt.
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.
- Tighten to 10 Nm (89 lb-in).
- Install the oil level indicator and tube front bolt.
- Tighten to 25 Nm (18 lb-ft).
- Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
- Connect the CKP sensor electrical connector.
- Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
- Connect the CKP sensor electrical connector.
- Install the 10 ignition coils and the 10 bolts.
- Tighten to 6 Nm (53 lb-in).
- Connect the 10 ignition coil electrical connectors.
- Install the LH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
- Connect the engine oil pressure (EOP) sensor electrical connector.
- Connect the cylinder head temperature (CHT) sensor electrical connector.
- Connect the electrical connector retainer to the coolant tube.
- Install the RH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
- Connect the CMP sensor electrical connector.
- Using a suitable floor crane, remove the engine from the engine stand.
- Lower and support the engine assembly on wood blocks.
- Install the special tool.
- Using a suitable floor crane raise the engine.
- Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
- Install the engine. For additional information, refer to ENGINE in the Installation portion of this section.
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.
NOTE:
LH shown, RH similar.
NOTE:
Be sure to tighten the bolts in 3 stages.
NOTE:
LH shown, RH similar.
LH cylinder head
RH cylinder head
All cylinder heads
CAUTION:
If the components are to be reinstalled, they must be installed into their original locations.
NOTE:
Camshaft shown installed to clarify camshaft roller follower position.
NOTE:
Lubricate the camshaft roller followers with clean engine oil prior to installation.
CAUTION:
If the components are to be reinstalled, they must be installed into their original locations.
NOTE:
Camshaft shown installed to clarify camshaft roller follower position.
NOTE:
Lubricate the camshaft roller followers with clean engine oil prior to installation.
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.
NOTE:
There are 61 links in each timing chain.
NOTE:
Be sure the upper half of the timing chain is below the tensioner guide dowel.
NOTE:
The LH timing chain tensioner arm has a bump near the dowel hole for identification.
NOTE:
Be sure the chain link and crankshaft sprocket timing marks are aligned.
NOTE:
The lower half of the timing chain must be positioned above the dowel.
CAUTION:
Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
CAUTION:
Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
CAUTION:
If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
CAUTION:
If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
CAUTION:
If the components are to be reinstalled, they must be installed into their original locations.
NOTE:
It may be necessary to use an inspection mirror to see the marks.
NOTE:
Install the balance shaft bearing caps in their original locations
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. To clean the sealing area, use 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.
NOTE:
Lubricate the new O-ring seal with clean engine oil prior to installation.
NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use 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.
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. Use a plastic scraping tool to remove all traces of old sealant.
NOTE:
If the valve 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.
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. Use a plastic scraping tool to remove all traces of old sealant.
NOTE:
If the valve 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.