Cylinder Head

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOLS

	Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
	Compressor, Valve Spring 303-1039
	Alignment Pins, Cylinder Head 303-1040 (SR-015486)
	Locking Tool, Camshaft Phaser Sprocket 303-1046S
	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
	Installer, Crankshaft Front Seal 303-635
	Installer, Front Cover Seal 303-335 (T88T-6701-A)
	Holding Tool, Crankshaft 303-448 (T93P-6303-A)

MATERIAL

Item	Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent	WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)	WSS-M97B51-A1
Silicone Gasket and Sealant TA-30 or equivalent	WSE-M4G323-A4
Metal Surface Prep ZC-31	-
Silicone Gasket Remover ZC-30	-
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA	-

All cylinder heads

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

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

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Fig 1: Positioning Cylinder Head Gaskets And Cylinder Heads Over Dowels And Installing Cylinder Head Bolts Loosely

Courtesy of FORD MOTOR CO.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.

NOTE: Tighten the bolts in 3 stages, in the sequence shown.

RH shown, LH similar.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 2: Identifying Cylinder Head Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.

LH cylinder head

Remove the special tool from the LH cylinder head.

Fig 3: Installing Special Tool Onto LH Cylinder Head
Courtesy of FORD MOTOR CO.
Install the hydraulic lash adjusters into the LH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  
  Fig 4: Identifying Hydraulic Lash Adjusters
  Courtesy of FORD MOTOR CO.
Position a new gasket and the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 5: Identifying Bolt Tightening/Loosening Sequence Of LH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Install the LH exhaust manifold shield and the 2 nuts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 6: Installing LH Exhaust Manifold Shield
  Courtesy of FORD MOTOR CO.

RH cylinder head

Remove the special tool from the RH cylinder head.

Fig 7: Installing Special Tool Onto RH Cylinder Head
Courtesy of FORD MOTOR CO.
Install the hydraulic lash adjusters into the RH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  
  Fig 8: Identifying Hydraulic Lash Adjusters
  Courtesy of FORD MOTOR CO.
Position a new gasket and the RH exhaust manifold and tighten the 8 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 9: Identifying Bolt Tightening/Loosening Sequence Of RH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Install the coolant tube and the stud bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 10: Identifying Coolant Tube Stud Bolt
  Courtesy of FORD MOTOR CO.

All cylinder heads

Using the special tool, position the crankshaft. Then remove the special tool.

Fig 11: Positioning Crankshaft With Special Tool
Courtesy of FORD MOTOR CO.
Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

NOTE: LH shown, RH similar.

Install the LH and RH camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the front camshaft bearing cap.
- Position the remaining camshaft bearing caps.
- Install the bolts loosely.
- Tighten to 10 Nm (89 lb-in) in the sequence shown.
  
  Fig 12: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequences
  Courtesy of FORD MOTOR CO.

CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE: LH shown, RH similar.

Fig 13: Identifying Camshaft Phaser Sprocket Bolt

Courtesy of FORD MOTOR CO.

Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight.

CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

NOTE: LH shown, RH similar.

Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 14: Installing Special Tool
  Courtesy of FORD MOTOR CO.

CAUTION: Timing chain procedures must be followed exactly or damage to 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 15: Compressing Tensioner Plunger Using Edge Of Vise

Courtesy of FORD MOTOR CO.

Compress the tensioner plunger, using a vise.
Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 16: Installing Retaining Clip On Tensioner
Courtesy of FORD MOTOR CO.
Remove the tensioner from the vise.
If the copper links are not visible, mark 2 links on one end and one link on the other end, and use as timing marks.

Fig 17: Identifying Timing Links When Copper Link Is Not Visible
Courtesy of FORD MOTOR CO.
Install the crankshaft sprocket, making sure the flange faces forward.

Fig 18: Installing Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the 4 bolts and the LH and RH timing chain guides.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 19: Identifying Bolts On LH And RH Timing Chain Guides
  Courtesy of FORD MOTOR CO.
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 20: Aligning Sprocket Timing Mark And Chain Link
Courtesy of FORD MOTOR CO.

NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

Fig 21: Identifying Timing Mark & Copper (Marked) Chain Links

Courtesy of FORD MOTOR CO.

Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.

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

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 22: Identifying LH Timing Chain Tensioner Bolts
  Courtesy of FORD MOTOR CO.
Remove the retaining clip from the LH timing chain tensioner.

Fig 23: Removing Timing Chain Tensioner Retaining Clip
Courtesy of FORD MOTOR CO.
Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.

Fig 24: Aligning Sprocket Timing Mark And Chain Link
Courtesy of FORD MOTOR CO.

NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.

NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.

Fig 25: Positioning RH Timing Chain

Courtesy of FORD MOTOR CO.

Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.
Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 26: Identifying RH Timing Chain Tensioner Bolts
  Courtesy of FORD MOTOR CO.
Remove the retaining clip from the RH timing chain tensioner.

Fig 27: Removing Timing Chain Tensioner Retaining Clip
Courtesy of FORD MOTOR CO.
As a post-check, verify correct alignment of all timing marks.

Fig 28: Checking Correct Alignment Of All Timing Marks
Courtesy of FORD MOTOR CO.
Install the crankshaft sensor ring on the crankshaft.

Fig 29: Installing Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
Using the special tool, install all of the camshaft roller followers.
- Lubricate the roller followers with clean engine oil prior to installation.
  
  Fig 30: Compressing Spring Using Special Tool
  Courtesy of FORD MOTOR CO.

CAUTION: 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. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: If the engine front cover is not secured within 4 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.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Fig 31: Identifying Silicone Sealant Application Locations

Courtesy of FORD MOTOR CO.

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.
Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.

Fig 32: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.
Tighten the engine front cover fasteners in sequence in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Fig 33: Identifying Engine Front Cover Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the 4 front oil pan bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
  
  Fig 34: Installing Oil Pan/Front Cover Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

NOTE: If not secured within 4 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 35: Identifying Silicone Gasket Application Points

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 36: Identifying Tighten Sequence Of LH Valve Cover Bolts
  Courtesy of FORD MOTOR CO.

Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Fig 37: Identifying Silicone Gasket Application Points

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.

Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 38: Identifying Tighten Sequence Of RH Valve Cover Bolts
  Courtesy of FORD MOTOR CO.
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 39: Installing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Use the special tools to install the crankshaft seal into the engine front cover.

Fig 40: Installing Crankshaft Front Seal Using Special Tools
Courtesy of FORD MOTOR CO.

Fig 41: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

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

Fig 42: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Tighten the new crankshaft pulley bolt in 4 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 43: Installing Crankshaft Pulley Bolt & Washer
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the LH camshaft position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 44: Locating Bolt And LH CMP Sensor
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 45: Identifying Bolt And RH CMP Sensor
  Courtesy of FORD MOTOR CO.
Position the crankshaft position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 46: Locating Crankshaft Position (CKP) Sensor And Bolt
  Courtesy of FORD MOTOR CO.
Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 47: Identifying Accessory Drive Belt Tensioner Bolts
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 48: Identifying Coolant Pump Pulley And Idler Pulley Bolts
  Courtesy of FORD MOTOR CO.
Position the oil level indicator and tube and install the bolt.
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 49: Locating Rear Oil Level Indicator Tube Bolt
  Courtesy of FORD MOTOR CO.
Install the oil level indicator and tube front bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 50: Locating Front Oil Level Indicator Tube Bolt
  Courtesy of FORD MOTOR CO.
Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.

NOTE: LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 51: Identifying Ignition Coils And Bolts
  Courtesy of FORD MOTOR CO.
Install the LH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 52: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
  Courtesy of FORD MOTOR CO.
Connect the cylinder head temperature (CHT) sensor electrical connector.

Fig 53: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 4 RH ignition coil electrical connectors.

Fig 54: Locating RH Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the electrical connector retainer to the coolant tube.

Fig 55: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
Courtesy of FORD MOTOR CO.
Connect the 2 engine wiring harness retainers to the RH valve cover studs.

Fig 56: Locating Engine Wiring Harness Retainers To RH Valve Cover
Courtesy of FORD MOTOR CO.
Connect the RH VCT solenoid electrical connector.

Fig 57: Locating RH VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Install the RH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 58: Identifying RH Radio Ignition Interference Capacitor And Stud Bolt
  Courtesy of FORD MOTOR CO.
Connect the RH CMP sensor electrical connector.

Fig 59: Identifying RH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Position the RH engine support insulator bracket and install the 4 bolts.
- Tighten to 63 Nm (46 lb-ft).
  
  Fig 60: Positioning RH Engine Support Insulator Bracket
  Courtesy of FORD MOTOR CO.
Position the RH engine support insulator and install the 4 bolts.
- Tighten to 63 Nm (46 lb-ft).
  
  Fig 61: Positioning RH Engine Support Insulator
  Courtesy of FORD MOTOR CO.
Using a suitable floor crane, remove the engine from the engine stand.
Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
  
  Fig 62: Identifying Flexplate/Flywheel Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the engine. For additional information, refer to ENGINE .