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Cylinder Heads: Installation

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    Both cylinder heads 

    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 correctly. Do not scratch the gasket.
    NOTE: LH shown, RH similar.
    Fig 1: Installing Head Gaskets Over Dowel Pins
    G03886853Courtesy of FORD MOTOR CO.
  1. Install the head gaskets over the dowel pins.
  2. Install the special tool.
    Fig 2: Installing Special Tool
    G03886854Courtesy of FORD MOTOR CO.
    3. 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: Removing Special Tool
    G03886856Courtesy of FORD MOTOR CO.
  3. Remove the special tool and loosely install cylinder head bolts.

    4. LH cylinder head 

  4. Tighten the cylinder head bolts in three stages in the sequence shown in Fig 4.
    • Stage 1: Tighten the bolts to 40 Nm (30 lb-ft).
    • Stage 2: Tighten the bolts an additional 90 degrees.
    • Stage 3: Tighten the bolts an additional 90 degrees.
      Fig 4: Tightening Cylinder Head Bolts
      G03886991Courtesy of FORD MOTOR CO.

    5. RH cylinder head 

  5. Tighten the cylinder head bolts in three stages in the sequence shown in Fig 5.
    • Stage 1: Tighten the bolts to 40 Nm (30 lb-ft).
    • Stage 2: Tighten the bolts an additional 90 degrees.
    • Stage 3: Tighten the bolts an additional 90 degrees.
      Fig 5: Tightening Cylinder Head Bolts
      G03886992Courtesy of FORD MOTOR CO.

    6. Both cylinder heads 

  6. Remove the lifting handles from both ends of the cylinder head.
    Fig 6: Installing/Removing Special Tools On Both Ends Of Cylinder Head
    G03885649Courtesy of FORD MOTOR CO.
    7. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
    Fig 7: Identifying Hydraulic Lash Adjusters
    G04583838Courtesy of FORD MOTOR CO.
  7. Install the hydraulic lash adjusters in their original locations.

    8. RH cylinder head 

  8. Using new gaskets, install the RH exhaust manifolds. Tighten the nuts in the sequence shown in Fig 8.
    Fig 8: Tightening Nuts In Sequence
    G03886495Courtesy of FORD MOTOR CO.

    9. LH cylinder head 

  9. Using new gaskets, install the LH exhaust manifold. Tighten the nuts in the sequence shown in Fig 9.
    Fig 9: Tightening Nuts In Sequence
    G03886497Courtesy of FORD MOTOR CO.

    10. Both cylinder heads 

    CAUTION: The timing chain procedures must be followed exactly or damage to the valves and pistons will result.
    CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
    Fig 10: Compressing Tensioner Plunger Using Edge Of Vise
    G03885344Courtesy of FORD MOTOR CO.
  10. Compress the tensioner plunger, using a vise.
  11. Install a retaining clip on the tensioner to hold the plunger during installation.
    Fig 11: Installing Retaining Clip On Tensioner
    G03881580Courtesy of FORD MOTOR CO.
  12. Remove the tensioner from the vise.
  13. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
    Fig 12: Marking Links When Copper Link Is Not Visible
    G03885317Courtesy of FORD MOTOR CO.
  14. Install the timing chain guides.
    Fig 13: View Of Timing Chain Guides With Torque Specifications
    G03906009Courtesy of FORD MOTOR CO.
  15. Preposition the camshafts.
    1. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.
    2. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
      Fig 14: Identifying Camshaft Timing Marks
      G03885320Courtesy of FORD MOTOR CO.
    16. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur. See Fig 15.
    NOTE: The number one piston is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
    Fig 15: Positioning Crankshaft
    G03885349Courtesy of FORD MOTOR CO.
  16. Position the crankshaft so the number one cylinder is at TDC with the special tool.
  17. Remove the crankshaft holding tool.
  18. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 16: Identifying Crankshaft Sprocket Flange
    G03881584Courtesy of FORD MOTOR CO.
  19. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
    Fig 17: Aligning Timing Mark On Outer Flange Of Crankshaft Sprocket With Single Copper Link On Chain
    G03886474Courtesy of FORD MOTOR CO.
    20. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
    Fig 18: Positioning Timing Chain On Camshaft Sprocket
    G03885324Courtesy of FORD MOTOR CO.
  20. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
    21. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 19: Installing LH Timing Chain Tensioner
    G03885938Courtesy of FORD MOTOR CO.
  21. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
  22. Remove the retaining clip from the LH timing chain tensioner.
    Fig 20: Removing Retaining Clip From LH Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  23. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
    Fig 21: Aligning Timing Mark On Crankshaft Sprocket With Single Copper Chain Link
    G03885327Courtesy of FORD MOTOR CO.
  24. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
    Fig 22: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark
    G03885328Courtesy of FORD MOTOR CO.
  25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 23: View Of RH Timing Chain Tensioner - With Torque Specification
    G03886280Courtesy of FORD MOTOR CO.
  26. Remove the retaining clip from the RH timing chain tensioner.
    Fig 24: View Of Retaining Clip AndTiming Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  27. As a post-check, verify correct alignment of all timing marks.
    Fig 25: Identifying Correct Alignment Of All Timing Marks
    G03906021Courtesy of FORD MOTOR CO.
  28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 26: Installing Special Tool Between Valve Spring Coils
    G03881599Courtesy of FORD MOTOR CO.
    29. NOTE: Lubricate the camshaft roller followers using clean engine oil.
    NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
  29. Install the camshaft roller followers.
    1. Install the special tool.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original locations.
      Fig 27: Installing Camshaft Roller Followers
      G03905495Courtesy of FORD MOTOR CO.
    30. CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.
  30. Install the 10 spark plugs.
    • Tighten the spark plugs to 18 Nm (13 lb-ft).
  31. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
    Fig 28: Identifying Balance Shaft And Gear Tooth Marks
    G03886484Courtesy of FORD MOTOR CO.
  32. Position the balance shaft on the journals.
    Fig 29: Positioning Balance Shaft On Journals
    G03886485Courtesy of FORD MOTOR CO.
  33. It may be necessary to use an inspection mirror to see the marks. Align the chalk mark on the balance shaft with the camshaft timing mark as shown in Fig 30.
    Fig 30: Aligning Mark On Balance Shaft With Camshaft Timing Mark
    G03886486Courtesy of FORD MOTOR CO.
  34. Install the bearing caps in their original location. Install the bolts and tighten the bolts in the sequence shown in Fig 31.
    Fig 31: Installing Bearing Caps
    G03886487Courtesy of FORD MOTOR CO.
  35. Install the crankshaft sensor ring on the crankshaft.
    Fig 32: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    36. NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 33: Locating Sealant Application Areas
    G03886057Courtesy of FORD MOTOR CO.
  36. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown in Fig 33.
  37. Install a new front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners.
    Fig 34: Installing Engine Front Cover
    G03881967Courtesy of FORD MOTOR CO.
  38. Tighten the engine front cover fasteners in sequence in three stages.
    1. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
    2. Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
    3. Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
      Fig 35: Tightening Engine Front Cover Fasteners In Sequence
      G03887022Courtesy of FORD MOTOR CO.
  39. Loosely install the bolts, then tighten in two stages, in the sequence shown in Fig 36.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 36: Identifying Tightening Sequence Of Bolts
      G03887023Courtesy of FORD MOTOR CO.
  40. Position the belt idler pulley and install the bolt.
    Fig 37: Installing Belt Idler Pulley
    G03885300Courtesy of FORD MOTOR CO.
  41. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 38: Installing Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  42. Using the special tools, install the crankshaft front seal.
    Fig 39: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool
    G03885953Courtesy of FORD MOTOR CO.
    43. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 40: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03886063Courtesy of FORD MOTOR CO.
  43. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  44. Use the special tool to install the crankshaft pulley.
    Fig 41: Installing Crankshaft Pulley Using Special Tool
    G03886064Courtesy of FORD MOTOR CO.
    45. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.
  45. Tighten the new crankshaft bolt in four stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
      Fig 42: Locating Crankshaft Pulley Bolt
      G04672695Courtesy of FORD MOTOR CO.
  46. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 43: Installing Coolant Pump Pulley On Coolant Pump With Torque Specification
    G03885980Courtesy of FORD MOTOR CO.
    47. NOTE: The front lower hole in the power steering pump is not used.
    Fig 44: Identifying Tightening Torque Of Power Steering Pump Bolts
    G03885304Courtesy of FORD MOTOR CO.
  47. Position the power steering pump and install the bolts.
  48. Apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    Fig 45: Identifying Proper Valve Cover Gasket Sealant Application
    G03948210Courtesy of FORD MOTOR CO.
    49. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 46: Identifying Silicone Gasket And Sealant Application Points
    G03886377Courtesy of FORD MOTOR CO.
  49. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  50. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 47: Installing Bolts
    G03886378Courtesy of FORD MOTOR CO.
  51. Tighten the bolts in the sequence shown in Fig 48.
    Fig 48: Tightening Bolts In Sequence
    G03906663Courtesy of FORD MOTOR CO.
  52. Apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    Fig 49: Applying Instant Adhesive Around Gasket Groove In Valve Cover
    G03905398Courtesy of FORD MOTOR CO.
    53. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 50: Identifying Silicone Gasket And Sealant Application Points
    G03886377Courtesy of FORD MOTOR CO.
  53. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  54. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 51: Identifying RH Valve Cover Bolts
    G03886406Courtesy of FORD MOTOR CO.
  55. Tighten the bolts in the sequence shown in Fig 52.
    Fig 52: Tightening Bolts In Sequence
    G03885262Courtesy of FORD MOTOR CO.
  56. Position the oil level indicator tube.
    Fig 53: Positioning Oil Level Indicator Tube
    G03887040Courtesy of FORD MOTOR CO.
  57. Install the bolt attaching the oil level indicator tube to the rear of the engine.
    Fig 54: Installing Bolt
    G03886860Courtesy of FORD MOTOR CO.
  58. Install the nut attaching the oil level indicator tube to the front of the engine.
    Fig 55: Installing Nut Attaching Oil Level Indicator Tube
    G03886859Courtesy of FORD MOTOR CO.
  59. Connect the crankcase vent tube to the valve cover.
    Fig 56: Connecting Crankcase Vent Tube To Valve Cover
    G03886367Courtesy of FORD MOTOR CO.
    60. NOTE: RH shown, LH similar.
    Fig 57: Identifying Radio Frequency Interference Capacitor
    G03885968Courtesy of FORD MOTOR CO.
  60. Install the radio frequency interference capacitors.
  61. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
  62. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 58: Locating CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  63. Connect the oil pressure switch electrical connector.
    Fig 59: Locating Oil Pressure Switch Electrical Connector
    G03886309Courtesy of FORD MOTOR CO.
  64. Connect the knock sensor electrical connector, if equipped.
    Fig 60: Locating KS Electrical Connector
    G03886734Courtesy of FORD MOTOR CO.
  65. Connect the RH radio frequency interference capacitor electrical connector.
    Fig 61: Locating Radio Frequency Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  66. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 62: Identifying Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  67. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 63: Locating Radio Frequency Interference Capacitor And Cylinder Head Temperature Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
    68. NOTE: LH shown, RH similar.
    Fig 64: Installing Cylinder Block Drain Plugs
    G03885975Courtesy of FORD MOTOR CO.
  68. Install the cylinder block drain plugs.
  69. Install the RH engine mount.
    • Tighten the bolts to 63 Nm (46 lb-ft).
  70. Install the special tool.
    Fig 65: Identifying Special Tool
    G03905704Courtesy of FORD MOTOR CO.
  71. Install the special tool.
    Fig 66: Identifying Special Tool
    G03905705Courtesy of FORD MOTOR CO.
  72. Install the special tool and remove the engine from the work stand.
    Fig 67: Installing Special Tool
    G03885993Courtesy of FORD MOTOR CO.
  73. Lower the engine onto wooden blocks.
  74. Remove the special tool.
    Fig 68: Identifying Special Tool
    G03905704Courtesy of FORD MOTOR CO.
  75. Remove the special tool.
    Fig 69: Identifying Special Tool
    G03905705Courtesy of FORD MOTOR CO.
  76. Install the special tool and raise the engine.
    Fig 70: Identifying Special Tool
    G03885604Courtesy of FORD MOTOR CO.
  77. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence shown in Fig 71.
    Fig 71: Installing Bolts
    G03886545Courtesy of FORD MOTOR CO.
  78. Install the engine. For additional information refer to Engine .
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