Cylinder Head: Installation
WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
- Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
- Remove any large deposits of silicone or gasket material with a plastic scraper.
- Apply silicone gasket remover, following package directions, and allow to set for several minutes.
- 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.
- 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.
- Inspect the cylinder head for distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
- Apply silicone gasket and sealant to the locations shown.
- Install a new head gasket.
- Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 15 Nm (11 lb-ft).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Turn 90 degrees.
- Stage 5: Turn an additional 90 degrees.
- Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
- Attach the wire harness retainer to the coolant outlet stud bolt.
- Connect the EGR coolant hose to the EGR valve.
- Connect the EGR valve electrical connector.
- Install the exhaust manifold. For additional information, refer to EXHAUST SYSTEM article.
- Install the generator. For additional information, refer to GENERATOR AND REGULATOR article.
- Install the intake manifold. For additional information, refer to Intake Manifold .
- Install the valve tappets in their original positions.
- Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps 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 to 7 Nm (62 lb-in).
- Stage 3: Tighten to 16 Nm (12 lb-ft).
- Install the special tool.
- Install the timing drive components. For additional information, refer to Timing Drive Components .
- Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
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.
NOTE:
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.
NOTE:
The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
NOTE:
Lubricate the bolts with clean engine oil prior to installation.
NOTE:
Lubricate the valve tappets with clean engine oil.
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.