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All cylinder heads

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    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.
    Fig 1: Installing Cylinder Head Bolts
    GF0005647Courtesy 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.
    2. NOTE: Be sure to tighten the bolts in 3 stages.
    Fig 2: Tightening Cylinder Head Bolts In Sequence
    GF0005648Courtesy of FORD MOTOR CO.
  2. Tighten the bolts in the sequence shown.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
    3. NOTE: LH shown, RH similar.
    Fig 3: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
  3. Install the cylinder block drain plugs.
    • Tighten to 24 Nm (18 lb-ft).
  4. Install the RH engine mount and the bolts.
    • Tighten to 63 Nm (46 lb-ft).
    Fig 4: Locating RH Engine Mount Bolts
    G04647883Courtesy of FORD MOTOR CO.


    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.
    Fig 1: Installing Identified Camshaft Roller Followers Onto RH Cylinder Head
    GF0005583Courtesy of FORD MOTOR CO.
  1. Install only the identified camshaft roller followers onto the RH cylinder head.
    2. 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.
    Fig 2: Identifying Camshaft Roller Followers Onto LH Cylinder Head
    GF0005584Courtesy of FORD MOTOR CO.
  2. Install only the identified camshaft roller followers onto the LH cylinder head.
  3. Install the LH and RH camshafts.
    • Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
  4. 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.
  5. Tighten the LH camshaft bearing cap bolts in 2 stages:
    • Stage 1: Tighten to 8 N.m (71 lb-in) in the sequence shown.
    • Stage 2: Tighten an additional 45 degrees.
    Fig 3: Identifying LH Camshaft Bearing Cap Bolt Removal/Installation Sequence
    G03920678Courtesy of FORD MOTOR CO.
  6. Tighten the RH camshaft bearing cap bolts in 2 stages:
    • Stage 1: Tighten to 8 N.m (71 lb-in) in the sequence shown.
    • Stage 2: Tighten an additional 45 degrees.
    Fig 4: Identifying RH Camshaft Bearing Cap Bolt Removal/Installation Sequence
    G03920676Courtesy of FORD MOTOR CO.
  7. Install the balance shaft drive gear onto the LH camshaft.
  8. Install both camshaft sprockets and camshaft sprocket bolts finger tight.
    9. 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 5: Compressing Tensioner Plunger
    G03885344Courtesy of FORD MOTOR CO.
  9. Compress the tensioner plunger, using a vise.
  10. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 6: Identifying Retaining Clip on Tensioner
    G03881580Courtesy of FORD MOTOR CO.
    11. NOTE: There are 61 links in each timing chain.
    Fig 7: Locating Timing Chain Marks
    G03885317Courtesy of FORD MOTOR CO.
  11. If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
  12. Install the timing chain guides and the 4 bolts.
    • Tighten to 10 N.m (89 lb-in).
    Fig 8: Locating Timing Chain Guides Bolts
    G03920972Courtesy of FORD MOTOR CO.
  13. 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.
    Fig 9: Identifying LH And RH Camshaft Timing Mark Position
    G04583473Courtesy of FORD MOTOR CO.
  14. Position the crankshaft with the special tool, then remove the tool.
    Fig 10: Positioning Crankshaft With Special Tool
    G03919963Courtesy of FORD MOTOR CO.
  15. Install the crankshaft sprocket, marking sure the flange faces forward.
    Fig 11: Identifying Crankshaft Sprocket
    G03919967Courtesy of FORD MOTOR CO.
  16. Install the lower end of the LH timing chain, aligning the timing marks.
    Fig 12: Aligning Timing Mark Of Crankshaft Sprocket With Single Copper Link On Chain
    G03886474Courtesy of FORD MOTOR CO.
    17. NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.
    Fig 13: Aligning Timing Marks On Sprocket With Marked Chain Links
    G03906562Courtesy of FORD MOTOR CO.
  17. Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
    18. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 14: Identifying LH Timing Chain Tensioner & Tensioner Arm
    G03919950Courtesy of FORD MOTOR CO.
  18. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
    19. 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.
    Fig 15: Aligning Timing Mark On Crankshaft Sprocket With Single Copper Chain Link
    G03885327Courtesy of FORD MOTOR CO.
  19. Install the RH (outer) timing chain on the crankshaft sprocket.
  20. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
    Fig 16: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark
    G03885328Courtesy of FORD MOTOR CO.
  21. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 17: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
    G03919951Courtesy of FORD MOTOR CO.
  22. Remove the retaining clips from the RH and LH timing chain tensioners.
    Fig 18: View Of Retaining Clip And Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  23. Check for correct alignment of all timing marks.
    Fig 19: Identifying Alignment Of All Timing Marks
    G03906021Courtesy of FORD MOTOR CO.
  24. Install the crankshaft sensor ring on the crankshaft.
    Fig 20: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    25. CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
    Fig 21: Identifying Camshaft Sprocket Bolt
    G03920660Courtesy of FORD MOTOR CO.
  25. Tighten the RH camshaft sprocket bolt in 2 stages:
    • Stage 1: Tighten to 40 N.m (30 lb-ft) in the sequence shown.
    • Stage 2: Tighten an additional 90 degrees.
    26. CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
    Fig 22: Identifying LH Camshaft Sprocket Bolt
    G03920661Courtesy of FORD MOTOR CO.
  26. Tighten the LH camshaft sprocket bolt in 2 stages:
    • Stage 1: Tighten to 40 N.m (30 lb-ft) in the sequence shown.
    • Stage 2: Tighten an additional 90 degrees.
  27. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    Fig 23: Crankshaft Positioned With Keyway At 6 O'clock Position
    G03919949Courtesy of FORD MOTOR CO.
  28. Remove the 2 bolts and the camshaft bearing cap.
    Fig 24: Identifying Bolts And Camshaft Bearing Cap
    G03920703Courtesy of FORD MOTOR CO.
    29. CAUTION: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
    Fig 25: Installing Roller Follower
    GF0005585Courtesy of FORD MOTOR CO.
  29. Using the special tool, install the roller follower.
    • Lubricate the camshaft roller follower with clean engine oil prior to installation.
  30. Position the camshaft bearing cap and install the bolts in 2 stages:

    7

    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
    Fig 26: Identifying Bolts And Camshaft Bearing Cap
    G03920703Courtesy of FORD MOTOR CO.
  31. Remove the 2 bolts and the camshaft bearing cap.
    Fig 27: Identifying Bolts And Camshaft Bearing Cap
    G03920706Courtesy of FORD MOTOR CO.
    32. CAUTION: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
    Fig 28: Installing Roller Follower
    GF0005586Courtesy of FORD MOTOR CO.
  32. Using the special tool, install the roller follower.
    • Lubricate the camshaft roller follower with clean engine oil prior to installation.
  33. 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.
    Fig 29: Identifying Bolts And Camshaft Bearing Cap
    G03920706Courtesy of FORD MOTOR CO.
    34. CAUTION: If the components are to be reinstalled, they must be installed into their original locations.
    Fig 30: Compressing Spring Using Special Tool
    G03919948Courtesy of FORD MOTOR CO.
  34. Using the special tool, install all of the remaining camshaft roller followers.
    • Lubricate the camshaft roller followers with clean engine oil prior to installation.
  35. Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
  36. Lubricate the balance shaft journals with clean engine oil.
  37. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
    Fig 31: Identifying Balance Shaft And Gear Tooth Marks
    G03886484Courtesy of FORD MOTOR CO.
  38. Position the balance shaft on the journals.
    39. NOTE: It may be necessary to use an inspection mirror to see the marks.
    Fig 32: Aligning Mark On Balance Shaft With Camshaft Timing Mark
    G03886486Courtesy of FORD MOTOR CO.
  39. Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.
    40. NOTE: Install the balance shaft bearing caps in their original locations
    Fig 33: Identifying Balance Shaft Bolt Loosening/Tightening Sequence
    G03920712Courtesy of FORD MOTOR CO.
  40. Install the bolts and tighten in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
    41. 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.
    Fig 34: Applying Bead of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface
    GF0005574Courtesy of FORD MOTOR CO.
  41. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
  42. 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.
    Fig 35: Installing Engine Front Cover Gasket
    GF0000367Courtesy of FORD MOTOR CO.
  43. 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).

    Fig 36: Identifying Tightening Sequence For Engine Front Cover Bolts
    GF0005575Courtesy of FORD MOTOR CO.
    Item 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
  44. 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.
    Fig 37: Identifying Tightening Sequence Of Front Oil Pan Bolts
    G03920544Courtesy of FORD MOTOR CO.
    45. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
    Fig 38: Locating Camshaft (CMP) Sensor Bolt
    G03920013Courtesy of FORD MOTOR CO.
  45. Install the camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
  46. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
    Fig 39: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  47. Using the special tools, install a new crankshaft seal into the engine front cover.
    Fig 40: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    48. 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.
    Fig 41: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  48. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  49. Use the special tool to install the crankshaft pulley.
    Fig 42: Using Special Tool To Install Crankshaft Pulley
    G03920552Courtesy of FORD MOTOR CO.
  50. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 43: Installing Crankshaft Pulley Bolt
    GF0002723Courtesy of FORD MOTOR CO.
  51. Position the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 44: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
  52. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 45: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
  53. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 46: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt
    G03920233Courtesy of FORD MOTOR CO.
    54. 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.
  54. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    55. 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.
    Fig 47: Identifying Silicone Gasket And Sealant Application Points
    GF0005568Courtesy of FORD MOTOR CO.
  55. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
  56. Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
    Fig 48: Identifying Valve Cover Fasteners Loosening/Tightening Sequence
    G03920595Courtesy of FORD MOTOR CO.
    57. 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.
  57. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    58. 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.
    Fig 49: Identifying Silicone Gasket And Sealant Application Points
    GF0005565Courtesy of FORD MOTOR CO.
  58. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
  59. Position the LH valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
    Fig 50: Identifying Valve Cover Fasteners Tightening Sequence
    G03920580Courtesy of FORD MOTOR CO.
  60. 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 N.m (89 lb-in).
    Fig 51: Locating Rear Oil Level Indicator Tube Bolt
    G03920295Courtesy of FORD MOTOR CO.
  61. Install the oil level indicator and tube front bolt.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 52: Locating Front Oil Level Indicator Tube Bolt
    G03920296Courtesy of FORD MOTOR CO.
  62. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
  63. Connect the CKP sensor electrical connector.
    Fig 53: Connecting CKP Sensor Electrical Connector
    GF0002667Courtesy of FORD MOTOR CO.
  64. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
  65. Connect the CKP sensor electrical connector.
    Fig 54: Connecting CKP Sensor Electrical Connector
    GF0002667Courtesy of FORD MOTOR CO.
  66. Install the 10 ignition coils and the 10 bolts.
    • Tighten to 6 N.m (53 lb-in).
    Fig 55: Locating Ignition Coils Bolts
    GF0005614Courtesy of FORD MOTOR CO.
  67. Connect the 10 ignition coil electrical connectors.
    Fig 56: Locating Ignition Coil Electrical Connectors
    GF0005613Courtesy of FORD MOTOR CO.
  68. Install the LH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 57: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
    G03920225Courtesy of FORD MOTOR CO.
  69. Connect the engine oil pressure (EOP) sensor electrical connector.
    Fig 58: Identifying Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03919846Courtesy of FORD MOTOR CO.
  70. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 59: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  71. Connect the electrical connector retainer to the coolant tube.
    Fig 60: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  72. Install the RH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 61: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
    G03920219Courtesy of FORD MOTOR CO.
  73. Connect the CMP sensor electrical connector.
    Fig 62: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  74. Using a suitable floor crane, remove the engine from the engine stand.
  75. Lower and support the engine assembly on wood blocks.
  76. Install the special tool.
    Fig 63: Identifying Special Tool
    G03920205Courtesy of FORD MOTOR CO.
  77. Using a suitable floor crane raise the engine.
  78. Install the flexplate or flywheel and the 8 bolts in the sequence shown.
    • Tighten to 80 N.m (59 lb-ft).
    Fig 64: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts
    G03920141Courtesy of FORD MOTOR CO.
  79. Install the engine. For additional information, refer to Engine  in the Installation portion of this article.
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