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Cylinder Head: Installation

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
    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.
    NOTE: 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.
  2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
  3. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to CYLINDER HEAD DISTORTION and CYLINDER BLOCK DISTORTION .
  4. Apply silicone gasket and sealant to the locations shown.
    Fig 1: Locating Silicone Gasket & Sealant Application Points
    G06261940Courtesy of FORD MOTOR CO.
  5. Install a new cylinder head gasket.
  6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages:
    • Stage 1: Tighten to 7 Nm (62 lb-in).
    • Stage 2: Tighten to 15 Nm (133 lb-in).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees
    • Stage 5: Turn an additional 90 degrees.
    NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. New cylinder head bolts must be installed.
    NOTE: Lubricate the bolts with clean engine oil prior to installation.
    Fig 2: Identifying Cylinder Head Bolt Tightening Sequence
    G06261941Courtesy of FORD MOTOR CO.
  7. Connect the coolant hose to the EGR valve.
  8. Connect the EGR valve electrical connector.
  9. Connect the upper radiator hose, coolant bypass hose and heater hose to the engine coolant outlet.
  10. Install the valve tappets.
    NOTE: Coat the valve tappets with clean engine oil prior to installation.
  11. Install the camshafts and bearing caps in their original locations and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
    • Stages 1: Tighten the camshaft bearing cap bolts until finger-tight.
    • Stages 2: Tighten to 7 Nm (62 lb-in).
    • Stages 3: Tighten to 16 Nm (142 lb-in).
    NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
    Fig 3: Identifying Camshaft Bearing Cap Bolt Tightening Sequence
    G06261942Courtesy of FORD MOTOR CO.
  12. Install the Camshaft Alignment Plate.
    Fig 4: Identifying Camshaft Alignment Plate
    G06261943Courtesy of FORD MOTOR CO.
  13. Install the VCT  solenoid and bolt.
    • Tighten to 10 Nm (89 lb-in).
  14. Install the timing drive components. For additional information, refer to Installation .
  15. Install the engine mount bracket and the 2 nuts.
    • Tighten to 103 Nm (76 lb-ft).
  16. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
    Fig 5: Identifying Engine Support Bar & Engine Lifting Brackets
    G06261944Courtesy of FORD MOTOR CO.
  17. Install the engine mount, nut and 2 bolts.
    • Tighten to 55 Nm (41 lb-ft).
  18. Lower the engine 25 mm (0.98 in).
  19. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
  20. Install the ground wire-to-engine mount bracket and bolt.
    • Tighten to 10 Nm (89 lb-in).
  21. Install the engine mount damper and the bolt.
    • Tighten to 23 Nm (17 lb-ft).
  22. Install the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD .
  23. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  24. Install the fuel supply rail. For additional information, refer to INSTALLATION .
  25. Install the generator. For additional information, refer to INSTALLATION .
  26. Connect the lower degas bottle hose to the degas bottle.
  27. Install the degas bottle and the nut and bolt.
    • Tighten to 9 Nm (80 lb-in).
  28. Connect the degas bottle-to-radiator hose.
  29. Fill and bleed the engine cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
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