Cylinder Head

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

SPECIAL TOOL(S) CHART

	Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
	Compressor, Valve Spring 303-1039
	Locking Tool, Camshaft Phaser Sprocket 303-1046
	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)
	Alignment Pins, Cylinder Head 303-1040 (SR-015486)

MATERIAL ITEM SPECIFICATION

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

All cylinder heads

Position the crankshaft with the special tool, then remove the tool.

Fig 1: Positioning Crankshaft With Special Tool
Courtesy of FORD MOTOR CO.

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 2: Using Special Tools to Position Cylinder Head Gaskets And Cylinder Heads Over Dowels

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.
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 3: Identifying Tightening Bolts Sequence
Courtesy of FORD MOTOR CO.

LH cylinder head

Remove the special tool from the LH cylinder head.

Fig 4: Removing Special Tool From 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 5: Installing Hydraulic Lash Adjusters Into LH Cylinder Head
Courtesy of FORD MOTOR CO.
Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
Fig 6: Identifying Bolt Tightening/Loosening Sequence Of LH Exhaust Manifold
Courtesy of FORD MOTOR CO.

RH cylinder head

Remove the special tool from the RH cylinder head.

Fig 7: Removing Special Tool From 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: Installing Hydraulic Lash Adjusters Into RH Cylinder Head
Courtesy of FORD MOTOR CO.
Position a new gasket, 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: Installing Coolant Tube And Stud Bolt
Courtesy of FORD MOTOR CO.

All cylinder heads

Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

NOTE: LH shown, RH similar.

Fig 11: Installing LH And RH Camshaft Bearing Caps In Sequence

Courtesy of FORD MOTOR CO.

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.

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

NOTE: LH shown, RH similar.

Fig 12: Installing VCT Phaser Sprockets And New VCT Phaser Sprocket Bolts Finger Tight

Courtesy of FORD MOTOR CO.

Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight.

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

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

NOTE: LH shown, RH similar.

Fig 13: Using Special Tool To Tighten LH And RH VCT Phaser Sprocket Bolts

Courtesy of FORD MOTOR CO.

Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

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 14: Compressing Tensioner Plunger Using A 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 15: 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 1 link on the other end, and use as timing marks.

Fig 16: Marking 2 Links On One End And 1 Link On Other End And Using As Timing Marks
Courtesy of FORD MOTOR CO.
Install the crankshaft sprocket, making sure the flange faces forward.

Fig 17: 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 18: Installing Bolts And 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 19: 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 20: 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.

Fig 21: Installing LH Timing Chain Tensioner And Bolts

Courtesy of FORD MOTOR CO.

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).
Remove the retaining clip from the LH timing chain tensioner.

Fig 22: Removing Retaining Clip From LH Timing Chain Tensioner
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 23: 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 24: Positioning RH Timing Chain On Camshaft Sprocket

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 25: Installing RH Timing Chain Tensioner And Bolts
Courtesy of FORD MOTOR CO.
Remove the retaining clip from the RH timing chain tensioner.

Fig 26: Removing Retaining Clip From RH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
As a post-check, verify correct alignment of all timing marks.

Fig 27: Checking Correct Alignment Of All Timing Marks
Courtesy of FORD MOTOR CO.
Install the crankshaft sensor ring on the crankshaft.

Fig 28: Installing Crankshaft Sensor Ring On Crankshaft
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 29: Using Special Tool To Install All Camshaft Roller Followers
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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. 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 30: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface

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 31: Positioning Engine Front Cover Onto Dowels
Courtesy of FORD MOTOR CO.
Tighten the engine front cover fasteners in the sequence shown 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 32: Tightening Engine Front Cover Fasteners In Sequence
Courtesy of FORD MOTOR CO.
Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
Fig 33: Identifying Installing Sequence Of Front Oil Pan/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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Fig 34: Applying Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head

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.

Fig 35: Identifying Tighten Sequence Of LH Valve Cover Bolts

Courtesy of FORD MOTOR CO.

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).

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

Fig 36: Applying Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head

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.

Fig 37: Identifying Tighten Sequence Of RH Valve Cover Bolts

Courtesy of FORD MOTOR CO.

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).
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 38: Lubricating Engine Front Cover And Crankshaft Seal Inner Lip With Clean Engine Oil
Courtesy of FORD MOTOR CO.
Use the special tools to install a new crankshaft seal into the engine front cover.

Fig 39: Using Special Tools To Install A New Crankshaft Seal Into Engine Front Cover
Courtesy of FORD MOTOR CO.

Fig 40: 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 41: Using Special Tool To Install 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 42: Installing Crankshaft Pulley Bolt & Washer
Courtesy of FORD MOTOR CO.

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

Fig 43: Installing LH Camshaft Position (CMP) Sensor And Bolt

Courtesy of FORD MOTOR CO.

Install the LH camshaft position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

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

Fig 44: Installing RH CMP Sensor And Bolt

Courtesy of FORD MOTOR CO.

Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
Position the crankshaft position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 45: Installing Crankshaft Position (CKP) Sensor 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 46: Installing Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
- Tighten to 25 Nm (18 lb-ft).
Fig 47: Installing Accessory Drive Belt Idler Pulleys, Coolant Pump Pulley And Bolts
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.
Connect the CKP sensor electrical connector.

Fig 48: Connecting CKP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 49: Installing Ignition Coils And Bolts

Courtesy of FORD MOTOR CO.

Install the 8 ignition coils and the 8 bolts.
- Tighten to 6 Nm (53 lb-in).
Connect the 4 LH ignition coil electrical connectors.

Fig 50: Connecting LH Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the LH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
Fig 51: Installing LH Radio Ignition Interference Capacitor And Stud Bolt
Courtesy of FORD MOTOR CO.
Connect the LH CMP sensor electrical connector.

Fig 52: Connecting LH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the engine oil pressure (EOP) sensor electrical connector.

Fig 53: Connecting Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the LH VCT solenoid electrical connector.

Fig 54: Connecting LH VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 2 engine wiring harness retainers to the LH valve cover studs.

Fig 55: Connecting 2 Engine Wiring Harness Retainers To LH Valve Cover Studs
Courtesy of FORD MOTOR CO.
Connect the cylinder head temperature (CHT) sensor electrical connector.

Fig 56: Connecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 4 RH ignition coil electrical connectors.

Fig 57: Connecting RH Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the electrical connector retainer to the coolant tube.

Fig 58: Connecting Electrical Connector Retainer To Coolant Tube
Courtesy of FORD MOTOR CO.
Connect the 2 engine wiring harness retainers from the RH valve cover studs.

Fig 59: Connecting 2 Engine Wiring Harness Retainers From RH Valve Cover Studs
Courtesy of FORD MOTOR CO.
Connect the RH VCT solenoid electrical connector.

Fig 60: Connecting 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 61: Installing RH Radio Ignition Interference Capacitor And Stud Bolt
Courtesy of FORD MOTOR CO.
Position the upper radiator hose support bracket and install the nut.
- Tighten to 10 Nm (89 lb-in).
Fig 62: Installing Upper Radiator Hose Support Bracket And Nut
Courtesy of FORD MOTOR CO.
Connect the RH CMP sensor electrical connector.

Fig 63: Connecting RH CMP Sensor Electrical Connector
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 64: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts
Courtesy of FORD MOTOR CO.
Install the engine. For additional information, refer to ENGINE .