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Cylinder Heads: Installation

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

    LH CYLINDER HEAD 

  1. Position the cylinder head gasket and the cylinder head.
    Fig 1: Positioning Cylinder Head Gasket And Cylinder Head
    G03274543Courtesy of FORD MOTOR CO.
    2. NOTE: Cylinder head bolts are a torque-to-yield design. New bolts must be installed.
  2. Install the 12 mm (0.47 in) bolts and tighten in the sequence shown in two stages.
    • Stage 1: Tighten to 12 Nm (9 lb-ft).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
      Fig 2: LH Cylinder Head Bolts Tightening Sequence
      G03973967Courtesy of FORD MOTOR CO.
  3. Install the two 8 mm (0.31 in) bolts.
    Fig 3: Installing Two 8 mm Bolts
    G03973968Courtesy of FORD MOTOR CO.
  4. Tighten the eight 12 mm (0.47 in) bolts in two stages in the sequence shown.
    • Stage 1: Tighten the bolts 90 degrees.
    • Stage 2: Tighten the bolts an additional 90 degrees.
      Fig 4: LH Cylinder Head Bolts Tightening Sequence - Torque Angle
      G03973969Courtesy of FORD MOTOR CO.
  5. Position the LH camshaft sprocket in the chain and install it on the camshaft.
    Fig 5: Positioning LH Camshaft Sprocket In Chain
    G03274547Courtesy of FORD MOTOR CO.
    6. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
    Fig 6: Installing Camshaft Sprocket Bolt
    G03274548Courtesy of FORD MOTOR CO.
  6. Install the camshaft sprocket bolt.
  7. Install the chain guide bolt.
    Fig 7: Installing Chain Guide Bolt
    G03274549Courtesy of FORD MOTOR CO.
  8. Install the ground strap and the bolt.
    Fig 8: Installing Ground Strap
    G03274550Courtesy of FORD MOTOR CO.
  9. Install the engine wiring harness pin-type retainer.
    Fig 9: Installing Engine Wiring Harness Pin-Type Retainer
    G03274551Courtesy of FORD MOTOR CO.
  10. Install the LH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD LH .

    11. RH CYLINDER HEAD 

  11. Position the cylinder head gasket and the cylinder head.
    Fig 10: Positioning Cylinder Head Gasket And Cylinder Head
    G03274552Courtesy of FORD MOTOR CO.
    12. NOTE: Cylinder head bolts are a torque-to-yield design. New bolts must be installed.
  12. Install the 12 mm (0.47 in) bolts and tighten in the sequence shown in two stages.
    • Stage 1: Tighten to 12 Nm (9 lb-ft).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
      Fig 11: RH Cylinder Head Bolts Tightening Sequence
      G03973976Courtesy of FORD MOTOR CO.
  13. Install the two 8 mm (0.31 in) bolts.
    Fig 12: Installing Two 8 mm Bolts
    G03973977Courtesy of FORD MOTOR CO.
  14. Tighten the eight 12 mm (0.47 in) bolts in two stages in the sequence shown.
    • Stage 1: Tighten the bolts 90 degrees.
    • Stage 2: Tighten the bolts and additional 90 degrees.
      Fig 13: RH Cylinder Head Bolts Tightening Sequence - Torque Angle
      G03973978Courtesy of FORD MOTOR CO.
  15. Position the RH camshaft sprocket in the chain and install it on the camshaft.
    Fig 14: Positioning RH Camshaft Sprocket In Chain
    G03274556Courtesy of FORD MOTOR CO.
    16. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
    Fig 15: Installing RH Camshaft Sprocket Bolt
    G03274557Courtesy of FORD MOTOR CO.
  16. Install the RH camshaft sprocket bolt.
  17. Install the chain guide bolt.
    Fig 16: Installing Chain Guide Bolt
    G03274558Courtesy of FORD MOTOR CO.
  18. Install the bracket and the bolt.
    Fig 17: Installing Bracket And Bolt
    G03274559Courtesy of FORD MOTOR CO.
  19. Install the LH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD - RH .

    20. BOTH CYLINDER HEADS 

    CAUTION: The RH camshaft sprocket bolt is a left-hand threaded bolt.
    NOTE: Use the Camshaft Gear Torque Adapter (303-565) to loosen the camshaft sprocket bolt.
    Fig 18: Loosening RH Camshaft Sprocket Bolt
    G03274560Courtesy of FORD MOTOR CO.
  20. If necessary, loosen the RH camshaft sprocket bolt.
    21. NOTE: The camshaft timing slots are off-center.
    Fig 19: Installing Special Tools On Front Of RH Cylinder Head
    G03274561Courtesy of FORD MOTOR CO.
  21. Position the camshaft timing slots below the centerline of the camshaft and install the special tools on the front of the RH cylinder head.
  22. Remove the RH fenderwell splash shield.
    Fig 20: Removing RH Fenderwell Splash Shield
    G03274562Courtesy of FORD MOTOR CO.
  23. Remove the RH camshaft tensioner.
    Fig 21: Removing RH Camshaft Tensioner
    G03274563Courtesy of FORD MOTOR CO.
    24. NOTE: Leave the top two special tool clamp bolts loose.
    Fig 22: Installing Special Tools On Rear Of RH Cylinder Head
    G03274564Courtesy of FORD MOTOR CO.
  24. Install the special tools on the rear of the RH cylinder head.
  25. Install the special tool.
    Fig 23: Installing Special Tool
    G03274565Courtesy of FORD MOTOR CO.
    26. CAUTION: The right -hand camshaft sprocket bolt is a left -hand threaded bolt.
    NOTE: Use the camshaft gear torque adapter (303-565) to tighten the camshaft sprocket bolt.
  26. Tighten the bolts.
    1. Tighten the special tool top two clamp bolts to 10 N.m (89 lb-in).
    2. Tighten the camshaft bolt.
      Fig 24: Tightening Camshaft Bolt
      G03274566Courtesy of FORD MOTOR CO.
  27. Install the RH camshaft tensioner.
    Fig 25: Installing RH Camshaft Tensioner
    G03274567Courtesy of FORD MOTOR CO.
  28. Install the RH fenderwell splash shield.
    Fig 26: Installing RH Fenderwell Splash Shield
    G03274568Courtesy of FORD MOTOR CO.
  29. Remove the LH camshaft tensioner.
    Fig 27: Removing LH Camshaft Tensioner
    G03274569Courtesy of FORD MOTOR CO.
  30. If necessary, loosen the LH camshaft sprocket bolt.
    Fig 28: Loosening LH Camshaft Sprocket Bolt
    G03274570Courtesy of FORD MOTOR CO.
    31. NOTE: Leave the top two special tool clamp bolts loose.
    Fig 29: Installing Special Tools On Front Of LH Cylinder Head
    G03274571Courtesy of FORD MOTOR CO.
  31. Install the special tools on the front of the LH cylinder head.
    32. NOTE: The camshaft timing slots are off-center.
    Fig 30: Installing Special Tools On Rear Of LH Cylinder Head
    G03274572Courtesy of FORD MOTOR CO.
  32. Position the camshaft timing slots below the centerline of the camshaft and install the special tools on the rear of the LH cylinder head.
  33. Install the special tool.
    Fig 31: Installing Special Tool
    G03274573Courtesy of FORD MOTOR CO.
  34. Tighten the bolts.
    1. Tighten the special tool top two clamp bolts to 10 N.m (89 lb-in).
    2. Tighten the camshaft bolt.
      Fig 32: Tightening Camshaft Bolt
      G03274574Courtesy of FORD MOTOR CO.
  35. Install the LH camshaft tensioner.
    Fig 33: Installing LH Camshaft Tensioner
    G03274575Courtesy of FORD MOTOR CO.
    36. NOTE: Install each roller follower in its original position.
    Fig 34: Installing Camshaft Roller Followers
    G03274576Courtesy of FORD MOTOR CO.
  36. Using the special tool, install the camshaft roller followers.
  37. Install the fuel injection supply manifold.
    1. Install the fuel injection supply manifold and the fuel injectors as an assembly.
    2. Install the fuel supply tube to the fuel manifold.
      Fig 35: Installing Fuel Injection Supply Manifold
      G03274577Courtesy of FORD MOTOR CO.
  38. Connect the fuel pulse damper vacuum hose.
    Fig 36: Connecting Fuel Pulse Damper Vacuum Hose
    G03274578Courtesy of FORD MOTOR CO.
  39. Connect the LH spark plug wires to the spark plugs.
  40. Install the oil level indicator tube and the bolt.
    Fig 37: Installing Oil Level Indicator Tube And Bolt
    G03274579Courtesy of FORD MOTOR CO.
  41. Connect the wiring harness casing to the LH cylinder head.
    Fig 38: Connecting Wiring Harness Casing To LH Cylinder Head
    G03274580Courtesy of FORD MOTOR CO.
  42. Install the accessory bracket and the bolts.
    Fig 39: Installing Accessory Bracket And Bolts
    G03274581Courtesy of FORD MOTOR CO.
  43. Position the wiring harness clip and install the bolt.
    Fig 40: Positioning Wiring Harness Clip
    G03274582Courtesy of FORD MOTOR CO.
  44. Install the thermostat housing and the bolts with the coolant bypass hose.
    Fig 41: Installing Thermostat Housing And Bolts With Coolant Bypass Hose
    G03274583Courtesy of FORD MOTOR CO.
  45. Connect the coolant bypass hose clamp.
    Fig 42: Connecting Coolant Bypass Hose Clamp
    G03274584Courtesy of FORD MOTOR CO.
  46. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
    Fig 43: Connecting Water Temperature Indicator Sender Unit And ECT Sensor Connectors
    G03274585Courtesy of FORD MOTOR CO.
  47. Connect the electrical harness retainers.
    Fig 44: Connecting Electrical Harness Retainers
    G03274586Courtesy of FORD MOTOR CO.
  48. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 45: Connecting CKP Sensor Connector
    G03274587Courtesy of FORD MOTOR CO.
  49. Attach the engine wiring harness retainer.
    Fig 46: Attaching Engine Wiring Harness Retainer
    G03274588Courtesy of FORD MOTOR CO.
  50. Attach the wiring harness retainers and connect the electrical connector.
    Fig 47: Attaching Wiring Harness Retainers And Connect Electrical Connector
    G03274589Courtesy of FORD MOTOR CO.
  51. Position the generator mounting bracket and generator assembly and install the bolts.
    Fig 48: Positioning Generator Mounting Bracket And Generator Assembly
    G03274590Courtesy of FORD MOTOR CO.
  52. Install the accessory drive belt tensioner.
    Fig 49: Installing Accessory Drive Belt Tensioner
    G03274591Courtesy of FORD MOTOR CO.
  53. Connect the generator electrical connections.
    Fig 50: Connecting Generator Electrical Connections
    G03274592Courtesy of FORD MOTOR CO.
  54. Install the RH valve cover. For additional information, refer to VALVE COVER - RH .
  55. Install the LH valve cover. For additional information, refer to VALVE COVER LH .
  56. Install the accessory drive belt. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
  57. Install the cooling fan shroud. For additional information, refer to ENGINE COOLING .
  58. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  59. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
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