LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2615 (Engine Mechanical - 3.0L (4V)) >> In-Vehicle Repair >> Cylinder Head - LH >> Installation

Cylinder Head - LH: Installation

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
    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 which make leak paths.
  1. Use a plastic scraping tool to remove all traces of the head gasket.
    • Clean all surfaces with metal surface prep.
  2. Position a new gasket and the cylinder head.
    3. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
    Fig 1: Identifying Cylinder Head Bolts Tightening Sequence
    G07781425Courtesy of FORD MOTOR CO.
  3. Install the bolts and tighten in 6 stages in the sequence shown in the illustration.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten 90 degrees.
    • Stage 3: Loosen one full turn.
    • Stage 4: Tighten to 40 Nm (30 lb-ft).
    • Stage 5: Tighten 90 degrees.
    • Stage 6: Tighten 90 degrees.
    4. NOTE: Installation of the oil level indicator may require the assistance of a second technician to align the tube with the orifice.
    NOTE: Install a new O-ring seal and lubricate with clean engine oil.
  4. Install the oil level indicator tube and install the stud bolt.
    • To install, tighten to 9 Nm (80 lb-in).
  5. Install the oil level indicator.
    6. NOTE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
  6. Install the hydraulic lash adjusters.
    • Lubricate the hydraulic lash adjusters with clean engine oil.
    7. NOTE: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
  7. Install the camshaft roller followers.
    • Lubricate the camshaft roller followers with clean engine oil.
  8. Position the camshaft phaser and sprocket onto the intake camshaft.
    • Install the 3 bolts finger-tight.
  9. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
    • Align the LH camshafts as shown in the illustration.
    Fig 2: Identifying LH Camshafts Are In Neutral Position
    G07781426Courtesy of FORD MOTOR CO.
    10. NOTE: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    NOTE: Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed or damage to the thrust caps can occur.
    Fig 3: Locating LH Camshaft Bearing Caps
    G07781427Courtesy of FORD MOTOR CO.
  10. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps.
    • Loosely install the bolts.
  11. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps.
    • Loosely install the bolts.
    Fig 4: Locating LH Camshaft Bearing Thrust Caps
    G07781428Courtesy of FORD MOTOR CO.
    12. NOTE: Make sure to tighten the camshaft bearing cap bolts in sequence in 2 stages.
    Fig 5: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
    G07781429Courtesy of FORD MOTOR CO.
  12. Tighten the LH camshaft bearing cap bolts in the sequence shown in the illustration in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Individually loosen and then tighten each camshaft bearing cap to 10 Nm (89 lb-in).
    13. NOTE: Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur.
    NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
    Fig 6: Remove/Install LH Camshaft Phaser, Sprocket And Bolts
    G07781430Courtesy of FORD MOTOR CO.
  13. Tighten the 3 LH camshaft phaser and sprocket bolts to 18 Nm (159 lb-in).
    14. NOTE: Clean the sealing surfaces with metal surface prep before installing a new press-in-place gasket.
    Fig 7: Locating Bolts And Camshaft Oil Seal Retainer
    G07781431Courtesy of FORD MOTOR CO.
  14. Install the camshaft oil seal retainer and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    15. NOTE: Lubricate the camshaft oil seal with clean engine oil.
    Fig 8: Installing Camshaft Oil Seal Using Special Tools
    G07781432Courtesy of FORD MOTOR CO.
  15. Using the Camshaft Oil Seal Installer, Camshaft Oil Seal Protector and the Power Steering Pump Pulley Installer, install the camshaft oil seal.
    16. NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
    Fig 9: Installing Camshaft Pulley Installer In Camshaft
    G07781433Courtesy of FORD MOTOR CO.
  16. Install the Camshaft Pulley Installer in the camshaft as shown in the illustration.
    • Adjust the collar on the Camshaft Pulley Installer screw to get the best thread engagement in the rear of the camshaft.
    17. NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
    NOTE: Only the roller collared nut from the Power Steering Pump Pulley Installer (211-185) is used on Camshaft Pulley Installer (303-458).
    Fig 10: Installing Special Tools Flush With End Of Camshaft
    G07781434Courtesy of FORD MOTOR CO.
  17. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer and on the end of the camshaft. Install the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer as shown in the illustration.
    • Using the Camshaft Pulley Installer, Power Steering Pump Pulley Installer and the Water Pump Pulley Spacer, install a new service coolant pump pulley flush with the end of the camshaft.
  18. Install the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS  in this service information.
  19. Install the coolant pump housing. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
  20. Install the LH catalytic converter. For additional information, refer to EXHAUST SYSTEM -- FUSION, MILAN & MKZ article.
  21. Install the lower intake manifold. For additional information, refer to LOWER INTAKE MANIFOLD  in this service information.
scientia non olet · About LEMON Manuals