Cylinder Heads

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

Fig 1: Identifying Special Service Tool

Courtesy of FORD MOTOR CO.

MATERIAL SPECIFICATION CHART

Item	Specification
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP	WSS-M2C153-H
Metal Surface Cleaner F4AZ-19A536-RA	WSE-M5B392-A
Silicone Gasket and Sealant F7AZ-19554-EA	WSE-M4G323-A4
Premium Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent	WSS-M97B41-A1
Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A	ESE-M1C171-A
Instant Adhesive E8AZ-19554-A	WSK-M2G402-A4

CAUTION: Make sure all coolant residue and foreign material is cleaned from the block surface and the cylinder bore.

CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. For additional information, refer to CYLINDER HEADS .

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal properly. Do not scratch the gasket.

NOTE: RH shown, LH similar.

Fig 2: Installing Head Gaskets Over Dowel Pins

Courtesy of FORD MOTOR CO.

Install the head gaskets over the dowel pins.

CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.

CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. For additional information, refer to CYLINDER HEADS .

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation.

Fig 3: Identifying LH Cylinder Head Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Tighten the LH cylinder head bolts in six stages in the sequence shown.
1. Stage 1: Tighten the bolts to 40 Nm (30 lb-ft).
2. Stage 2: Tighten the bolts an additional 90 degrees (1/4 turn).
3. Stage 3: Back out all the bolts one full turn (360 degrees).
4. Stage 4: Tighten the bolts to 40 Nm (30 lb-ft).
5. Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
6. Stage 6: Tighten the bolts an additional 90 degrees (1/4 turn).

CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.

CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. For additional information, refer to CYLINDER HEADS .

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation.

Fig 4: Identifying RH Cylinder Head Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Tighten the RH cylinder head bolts in six stages in the sequence shown.
1. Stage 1: Tighten the bolts to 40 Nm (30 lb-ft).
2. Stage 2: Tighten the bolts an additional 90 degrees (1/4 turn).
3. Stage 3: Back out all the bolts one full turn (360 degrees).
4. Stage 4: Tighten the bolts to 40 Nm (30 lb-ft).
5. Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
6. Stage 6: Tighten the bolts an additional 90 degrees (1/4 turn).
Install the hydraulic lash adjusters in their original locations.

Fig 5: Installing Hydraulic Lash Adjusters In Their Original Locations
Courtesy of FORD MOTOR CO.
Using new gaskets, install the RH exhaust manifold. Tighten the nuts in the sequence shown.

Fig 6: Installing RH Exhaust Manifold
Courtesy of FORD MOTOR CO.
Install the RH exhaust manifold heat shield and the bolts.

Fig 7: Installing RH Exhaust Manifold Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
Inspect the O-ring seals. Install new seals if necessary.

Fig 8: Inspecting O-Ring Seals
Courtesy of FORD MOTOR CO.
Install the coolant tube and the nut.

Fig 9: Installing Coolant Tube And Nut
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring seal with clean engine oil.

Fig 10: Installing Oil Level Indicator Tube And Retaining Bolt

Courtesy of FORD MOTOR CO.

Install the oil level indicator tube and the retaining bolt.
Using new gaskets, install the LH exhaust manifold. Tighten the nuts in the sequence shown.

Fig 11: Installing LH Exhaust Manifold
Courtesy of FORD MOTOR CO.
Install the LH exhaust manifold heat shield and the bolts.

Fig 12: Installing LH Exhaust Manifold Heat Shield
Courtesy of FORD MOTOR CO.

CAUTION: The timing chain procedures must be followed exactly or damage to the valves and pistons will result.

CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Fig 13: Compressing Tensioner Plunger

Courtesy of FORD MOTOR CO.

Compress the tensioner plunger, using an edge of a vise.
Using a small screwdriver or pick, push back and hold the ratchet mechanism.

Fig 14: Pushing Back And Hold Ratcheting Mechanism
Courtesy of FORD MOTOR CO.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 15: Pushing Ratchet Arm Back Into Tensioner Housing
Courtesy of FORD MOTOR CO.
Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.

Fig 16: Installing A Paper Clip Into Hole
Courtesy of FORD MOTOR CO.
Remove the tensioner from the vise.
If the copper links are not visible, mark one link on one end and one link on the other end, and use as the timing marks.

Fig 17: Identifying Copper Links On Timing Chain
Courtesy of FORD MOTOR CO.
Position the crankshaft with the special tool.

Fig 18: Positioning Crankshaft With Special Tool
Courtesy of FORD MOTOR CO.
Install the crankshaft sprocket, make sure the timing mark faces forward.

Fig 19: Installing Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position.
Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.

Fig 20: Aligning Camshaft Sprocket Timing Marks
Courtesy of FORD MOTOR CO.
Install the timing chain guides.
1. Position the LH timing chain guide.
2. Install and tighten the bolts.
3. Position the RH timing chain guide.
4. Install and tighten the bolts.
Fig 21: Installing Timing Chain Guides
Courtesy of FORD MOTOR CO.
Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

Fig 22: Positioning LH (Inner) Timing Chain On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

Fig 23: Installing LH Timing Chain On Camshaft Sprocket
Courtesy of FORD MOTOR CO.

NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Fig 24: Installing LH Timing Chain Tensioner

Courtesy of FORD MOTOR CO.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
Remove the LH retaining pin from the timing chain tensioner.

Fig 25: Removing LH Retaining Pin From Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

Fig 26: Positioning RH (Outer) Timing Chain On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

Fig 27: Installing RH Timing Chain On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.

Fig 28: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
Remove the RH retaining pin from the timing chain tensioner.

Fig 29: Removing RH Retaining Pin From Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
As a post-check, make sure the copper (marked) links on the timing chains line up with the timing marks on the crankshaft and camshaft sprockets.

Fig 30: Identifying Copper (Marked) Links On Timing Chains Line
Courtesy of FORD MOTOR CO.
Position the crankshaft sensor ring on the crankshaft.

Fig 31: Positioning Crankshaft Sensor Ring On Crankshaft
Courtesy of FORD MOTOR CO.

NOTE: If the bolts are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Fig 32: Applying Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant along the head-to-block surface and the oil pan-to-cylinder block surface as specified.
Using new gaskets, install the engine front cover. Install the fasteners finger-tight.

Fig 33: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.
Tighten the front cover bolts and stud bolts in the sequence shown.

Fig 34: Identifying Front Cover Bolts And Stud Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Lubricate the front cover and the front oil seal inner lip with clean engine oil.

Fig 35: Identifying Front Cover Oil Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install the front oil seal into the engine front cover.

Fig 36: Installing Front Oil Seal Into Engine Front Cover
Courtesy of FORD MOTOR CO.

NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Fig 37: Applying Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
Using the special tool, install the crankshaft pulley.

Fig 38: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.

NOTE: Use special tool 303-D055 to hold the crankshaft pulley.

Fig 39: Installing Crankshaft Pulley Bolt And Washer

Courtesy of FORD MOTOR CO.

Install the crankshaft pulley bolt and washer. Tighten the bolt in four stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen one full turn (360 degrees).
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees (1/4 turn).

NOTE: Lubricate the camshaft roller followers, using clean engine oil.

Fig 40: Rotating Camshaft Lobe Directly Away From Roller Follower

Courtesy of FORD MOTOR CO.

Rotate the crankshaft until the cam lobe is directly away from the roller follower.
Install the special tool between the valve spring coils to prevent valve stem seal damage.

Fig 41: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.

NOTE: Install the roller followers into their original locations.

Fig 42: Installing Roller Followers Into Their Original Locations

Courtesy of FORD MOTOR CO.

Using the special tool to compress the valve spring, install the camshaft roller followers.
Install the spark plugs.

Fig 43: Installing Spark Plugs
Courtesy of FORD MOTOR CO.
If a new gasket is being installed, apply adhesive completely around the gasket groove in the LH valve cover.

Fig 44: Applying Adhesive Completely Around Gasket Groove
Courtesy of FORD MOTOR CO.

NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Fig 45: Applying Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the LH valve cover gasket surface, in two places, where the engine front cover meets the cylinder head.
Install the LH valve cover and tighten the bolts in the sequence shown.

Fig 46: Installing LH Valve Cover And Tighten Bolts
Courtesy of FORD MOTOR CO.
If a new gasket is being installed, apply adhesive completely around the gasket groove in the RH valve cover.

Fig 47: Applying Adhesive Completely Around Gasket Groove
Courtesy of FORD MOTOR CO.

NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Fig 48: Applying Silicone Gasket And Sealant To RH Valve Cover Gasket Surface

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the RH valve cover gasket surface, in two places, where the engine front cover meets the cylinder head.
Install the RH valve cover and tighten the bolts in the sequence shown.

Fig 49: Installing RH Valve Cover
Courtesy of FORD MOTOR CO.
Install the RH engine support insulator bracket and the bolts.

Fig 50: Installing RH Engine Support Insulator Bracket
Courtesy of FORD MOTOR CO.
Install new intake manifold gaskets.

Fig 51: Installing Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.
Install the intake manifold and tighten the bolts in the sequence shown.

Fig 52: Installing Intake Manifold
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring seal with clean engine coolant.

Fig 53: Installing Thermostat Housing And Bolts

Courtesy of FORD MOTOR CO.

Install the thermostat housing and the bolts.

NOTE: Apply dielectric compound to the inside of the coil boots.

Fig 54: Installing Eight Ignition Coils And Bolts

Courtesy of FORD MOTOR CO.

Install all eight ignition coils and the bolts.
Position the fuel charging wiring harness on the top of the engine.
- Connect the harness locators to the engine.
Fig 55: Connecting Harness Locators To Engine
Courtesy of FORD MOTOR CO.
Connect the ground wire.

Fig 56: Connecting Ground Wire
Courtesy of FORD MOTOR CO.
Position the starter wiring harness and connect the wiring harness retainers.

Fig 57: Positioning Starter Wiring Harness And Connect Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the LH fuel injector and the coil-on-plug electrical connectors. Install the wiring harness retainers.

Fig 58: Connecting LH Fuel Injector And Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the RH fuel injector, coil-on-plug and ground electrical connectors. Install the wiring harness retainers.

Fig 59: Install Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Install the throttle body adapter and bolts.

Fig 60: Installing Throttle Body Adapter And Bolts
Courtesy of FORD MOTOR CO.
Install the bolt.

Fig 61: Installing Bolt
Courtesy of FORD MOTOR CO.
Connect the coolant hose.

Fig 62: Connecting Coolant Hose (1 Of 2)
Courtesy of FORD MOTOR CO.
Connect the coolant hoses.

Fig 63: Connecting Coolant Hoses (2 Of 2)
Courtesy of FORD MOTOR CO.
Connect the knock sensor (KS) electrical connector and install the harness retainer to the intake manifold.

Fig 64: Installing Knock Sensor Connector
Courtesy of FORD MOTOR CO.
Connect the cylinder head temperature (CHT) sensor electrical connector.

Fig 65: Connecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the EGR system module and fuel pressure sensor electrical connectors.

Fig 66: Connecting EGR System Module And Fuel Pressure Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Position the vacuum harness on the engine and connect the EGR system module and fuel pressure sensor vacuum fittings.

Fig 67: Positioning Vacuum Harness On Engine
Courtesy of FORD MOTOR CO.
Install the positive crankcase ventilation (PCV) tube and connect the vacuum tube to the throttle body adapter.

Fig 68: Installing Positive Crankcase Ventilation (PCV) Tube
Courtesy of FORD MOTOR CO.
Connect the throttle position (TP) sensor and the electronic throttle body electrical connectors.

Fig 69: Connecting Throttle Position (TP) Sensor
Courtesy of FORD MOTOR CO.
Install the brake booster vacuum hose and bolt.

Fig 70: Installing Brake Booster Vacuum Hose
Courtesy of FORD MOTOR CO.
Install the exhaust gas recirculation (EGR) tube to the exhaust manifold and the EGR system module.

Fig 71: Installing Exhaust Gas Recirculation (EGR) Tube
Courtesy of FORD MOTOR CO.
Position the coolant pump pulley on the coolant pump and install the bolts.

Fig 72: Installing Coolant Pump Pulley On Coolant Pump
Courtesy of FORD MOTOR CO.
Connect the camshaft position (CMP) sensor electrical connector.

Fig 73: Connecting Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the generator and the bolts.

Fig 74: Installing Generator And Bolts
Courtesy of FORD MOTOR CO.
Install the idler pulleys and the bolts.

Fig 75: Installing Idler Pulleys And Bolts
Courtesy of FORD MOTOR CO.
Install the generator bracket and the bolts.

Fig 76: Installing Generator Bracket And Bolts
Courtesy of FORD MOTOR CO.
Connect the generator electrical connections.

Fig 77: Connecting Generator Electrical Connections
Courtesy of FORD MOTOR CO.
Install the upper radiator hose bracket and the radio interference capacitor.

Fig 78: Installing Upper Radiator Hose Bracket
Courtesy of FORD MOTOR CO.
Install the crankcase air inlet tube.

Fig 79: Installing Crankcase Air Inlet Tube
Courtesy of FORD MOTOR CO.
Position the wiring harness and connect the retainers.

Fig 80: Positioning Wiring Harness And Connect Retainers
Courtesy of FORD MOTOR CO.
Connect the A/C compressor and the crankshaft position (CKP) sensor electrical connector.

Fig 81: Connecting A/C Compressor And Crankshaft Position
Courtesy of FORD MOTOR CO.
Install the power steering reservoir bracket, radio interference capacitor, ground cable and nut.

Fig 82: Installing Power Steering Reservoir Bracket
Courtesy of FORD MOTOR CO.
Install the power steering pump.

Fig 83: Installing Power Steering Pump
Courtesy of FORD MOTOR CO.
Using the special tool, install a new seal on the power steering pressure (PSP) hose fitting.

Fig 84: Installing Seal On Power Steering Pressure (PSP) Hose Fitting
Courtesy of FORD MOTOR CO.
Connect the return and pressure hoses to the power steering pump.

Fig 85: Connecting Return And Pressure Hoses To Power Steering Pump
Courtesy of FORD MOTOR CO.
Install the power steering hose support bracket and the nuts.

Fig 86: Installing Power Steering Hose Support Bracket
Courtesy of FORD MOTOR CO.
Connect the oil pressure sensor electrical connector.
Install the wiring harness bracket and nuts.

Fig 87: Installing Wiring Harness Bracket And Nuts
Courtesy of FORD MOTOR CO.
Install the accessory drive belt.

NOTE: RH is shown, LH is similar.

Fig 88: Installing Engine Lift Brackets

Courtesy of FORD MOTOR CO.

Install the engine lift brackets.
Attach the special tool to a floor crane and the engine, and remove the engine from the engine stand.

Fig 89: Removing Engine From Engine Stand
Courtesy of FORD MOTOR CO.
Install the rear engine cover.

Fig 90: Installing Rear Engine Cover
Courtesy of FORD MOTOR CO.
Position the flexplate and install the bolts in two stages.
1. Stage 1: Loosely install the bolts.
2. Stage 2: Tighten the bolts in the sequence shown.
Fig 91: Installing Bolts In Sequence
Courtesy of FORD MOTOR CO.
Install the engine. For additional information, refer to ENGINE .