Cylinder Head

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, 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)
	Holding Tool, Crankshaft 303--448 (T93P-6303-A)
	Compressor, Valve Spring 303--1039
	Alignment Pins, Cylinder Head 303--1040 (SR-015486)
	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
	Installer, Crankshaft Front Seal 303--635
	Installer, Front Cover Seal 303--335 (T88T-6701-A)

MATERIAL

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 or equivalent	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

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: Installing Cylinder Head Bolts

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: Be sure to tighten the bolts in 3 stages.

Tighten the bolts in the sequence shown.
- 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.

NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 3: Locating Cylinder Block Drain Plugs
  Courtesy of FORD MOTOR CO.
Install the RH engine mount and the bolts.
- Tighten to 63 Nm (46 lb-ft).
  
  Fig 4: Installing RH Engine Mount And Bolts
  Courtesy of FORD MOTOR CO.

LH cylinder head

Remove the special tool from the LH cylinder head.

Fig 5: 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 6: Identifying Hydraulic Lash Adjusters
  Courtesy of FORD MOTOR CO.
Position a new gasket, the LH exhaust manifold and tighten the 10 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 7: Identifying LH Exhuast Manifold Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.

RH cylinder head

Remove the special tool from the RH cylinder head.

Fig 8: 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 9: Identifying Hydraulic Lash Adjusters
  Courtesy of FORD MOTOR CO.
Position a new gasket, the RH exhaust manifold and tighten the 10 nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 10: Identifying RH Exhaust Manifold Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the coolant tube and the stud bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 11: Identifying Coolant Tube Stud Bolt
  Courtesy of FORD MOTOR CO.

All cylinder heads

CAUTION: If the components are to be reinstalled, they must be installed into their original locations.

NOTE: Camshaft shown installed to clarify camshaft roller follower position.

NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.

Fig 12: Installing Identified Camshaft Roller Followers Onto RH Cylinder Head

Courtesy of FORD MOTOR CO.

Install only the identified camshaft roller followers onto the RH cylinder head.

CAUTION: If the components are to be reinstalled, they must be installed into their original locations.

NOTE: Camshaft shown installed to clarify camshaft roller follower position.

NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.

Fig 13: Installing Identified Camshaft Roller Followers Onto LH Cylinder Head

Courtesy of FORD MOTOR CO.

Install only the identified camshaft roller followers onto the LH cylinder head.
Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
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 the LH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.
  
  Fig 14: Identifying LH Camshaft Bearing Cap Bolt Removing/Installation Sequence
  Courtesy of FORD MOTOR CO.
Tighten the RH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.
  
  Fig 15: Identifying RH Camshaft Bearing CapBolt Removing/Installation Sequence
  Courtesy of FORD MOTOR CO.
Install the balance shaft drive gear onto the LH camshaft.
Install both camshaft sprockets and camshaft sprocket bolts finger tight.

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 16: 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 17: Installing Retaining Clip On Tensioner
Courtesy of FORD MOTOR CO.

NOTE: There are 61 links in each timing chain.

Fig 18: Marking Links When Copper Link Is Not Visible

Courtesy of FORD MOTOR CO.

If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
Install the timing chain guides and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 19: Installing Timing Chain Guides And Bolts
  Courtesy of FORD MOTOR CO.
Preposition the camshafts.
1. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
2. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.
  
  Fig 20: Identifying Timing Mark
  Courtesy of FORD MOTOR CO.
Position the crankshaft with the special tool, then remove the tool.

Fig 21: Positioning Cranskshaft With Special Tool
Courtesy of FORD MOTOR CO.
Install the crankshaft sprocket, marking sure the flange faces forward.

Fig 22: Installing Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the lower end of the LH timing chain, aligning the timing marks.

Fig 23: Aligning Timing Mark On Outer Flange Of Crankshaft Sprocket With Single Copper Link On Chain
Courtesy of FORD MOTOR CO.

NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.

Fig 24: Installing LH Timing Chain On Camshaft Sprocket With Chain (Marked) Links

Courtesy of FORD MOTOR CO.

Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.

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 25: Identifying LH Timing Chain Tensioner Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

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

Fig 26: Aligning Timing Mark On Crankshaft Sprocket With Single Copper Chain Link

Courtesy of FORD MOTOR CO.

Install the RH (outer) timing chain on the crankshaft sprocket.
Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.

Fig 27: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark
Courtesy of FORD MOTOR CO.
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 28: Identifying RH Timing Chain Tensioner Bolts
  Courtesy of FORD MOTOR CO.
Remove the retaining clips from the RH and LH timing chain tensioners.

Fig 29: Removing Timing Chain Tensioner Retaining Clip
Courtesy of FORD MOTOR CO.
Check for correct alignment of all timing marks.

Fig 30: Identifying All Timing Marks
Courtesy of FORD MOTOR CO.
Install the crankshaft sensor ring on the crankshaft.

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

CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.

Tighten the RH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft) in the sequence shown.
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 32: Locating RH Camshaft Sprocket Bolt
  Courtesy of FORD MOTOR CO.

CAUTION: Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.

Tighten the LH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft) in the sequence shown.
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 33: Identifying LH Camshaft Sprocket Bolt
  Courtesy of FORD MOTOR CO.
Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.

Fig 34: Positioning Crankshaft Keyway At 6 O'clock Position
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the camshaft bearing cap.

Fig 35: Identifying Bolts And Camshaft Bearing Cap
Courtesy of FORD MOTOR CO.

CAUTION: If the components are to be reinstalled, they must be installed into their original locations.

Using the special tool, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.
  
  Fig 36: Installing Roller Follower
  Courtesy of FORD MOTOR CO.
Position the camshaft bearing cap and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 37: Identifying Bolts And Camshaft Bearing Cap
  Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the camshaft bearing cap.

Fig 38: Identifying Bolts And Camshaft Bearing Cap
Courtesy of FORD MOTOR CO.

CAUTION: If the components are to be reinstalled, they must be installed into their original locations.

Using the special tool, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.
  
  Fig 39: Installing Roller Follower
  Courtesy of FORD MOTOR CO.
Position the camshaft bearing cap and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 40: Identifying Bolts And Camshaft Bearing Cap
  Courtesy of FORD MOTOR CO.

CAUTION: If the components are to be reinstalled, they must be installed into their original locations.

Using the special tool, install all of the remaining camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.
  
  Fig 41: Compressing Spring Using Special Tool
  Courtesy of FORD MOTOR CO.
Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
Lubricate the balance shaft journals with clean engine oil.
Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.

Fig 42: Identifying Balance Shaft And Gear Tooth Marks
Courtesy of FORD MOTOR CO.
Position the balance shaft on the journals.

NOTE: It may be necessary to use an inspection mirror to see the marks.

Fig 43: Aligning Mark On Balance Shaft With Camshaft Timing Mark

Courtesy of FORD MOTOR CO.

Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.

NOTE: Install the balance shaft bearing caps in their original locations

Install the bolts and tighten in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 44: Identifying Bolt Loosening/Tightening Sequence
  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 45: Identifying Silicone Gasket And Sealant Application Location

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant along the cylinder head-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 46: 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 47: Identifying Front Cover Fasteners Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the front 4 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 48: Identifying Installing Sequence Of Oil Pan/Front Cover Bolts
Courtesy of FORD MOTOR CO.

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

Install the camshaft position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 49: Identifying Bolt And RH CMP Sensor
  Courtesy of FORD MOTOR CO.
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 50: Installing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install a new crankshaft seal into the engine front cover.

Fig 51: Installing Crankshaft Front Seal Using Special Tools
Courtesy of FORD MOTOR CO.

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 52: 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 53: 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 54: Installing Crankshaft Pulley Bolt & Washer
  Courtesy of FORD MOTOR CO.
Position the crankshaft position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 55: 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 56: 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 57: Identifying Coolant Pump Pulley And Idler Pulley 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 the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 58: Identifying Silicone Gasket And Sealant Application Surface

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 59: Identifying Valve Cover Fasteners Tightening Sequence
  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 60: Identifying Silicone Gasket And Sealant Application Surface

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Position the LH valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 61: Identifying Valve Cover Fasteners Tightening Sequence
  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 62: 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 63: 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.
Connect the CKP sensor electrical connector.

Fig 64: Locating CKP Sensor Electrical Connector
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 65: Locating CKP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the 10 ignition coils and the 10 bolts.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 66: Installing Ignition Coils And Bolts
  Courtesy of FORD MOTOR CO.
Connect the 10 ignition coil electrical connectors.

Fig 67: Connecting 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 68: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
  Courtesy of FORD MOTOR CO.
Connect the engine oil pressure (EOP) sensor electrical connector.

Fig 69: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the cylinder head temperature (CHT) sensor electrical connector.

Fig 70: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the electrical connector retainer to the coolant tube.

Fig 71: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
Courtesy of FORD MOTOR CO.
Install the RH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 72: Identifying RH Radio Ignition Interference Capacitor And Stud Bolt
  Courtesy of FORD MOTOR CO.
Connect the CMP sensor electrical connector.

Fig 73: Identifying RH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Using a suitable floor crane, remove the engine from the engine stand.
Lower and support the engine assembly on wood blocks.
Install the special tool.

Fig 74: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Using a suitable floor crane raise the engine.
Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
  
  Fig 75: Identifying flexplate Or flywheel Bolt Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the engine. For additional information, refer to ENGINE .