Cylinder Heads: Installation

All cylinder heads 

CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. 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: The RH head gasket is shown; the LH head gasket is similar.
Fig 1: Installing Head Gasket Over Dowel Pins
Courtesy of FORD MOTOR CO.
1. Install the head gasket 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 cylinder block must be clean. 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.
NOTE: The RH cylinder head is shown; the LH cylinder head is similar.
Fig 2: Installing Cylinder Head On Dowels And Head Gasket
Courtesy of FORD MOTOR CO.
2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.

   LH cylinder head 

NOTE: Make sure to tighten the bolts in sequence in three stages.
3. Tighten the LH 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 3: Tightening LH Bolts In Sequence

     Courtesy of FORD MOTOR CO.

   RH cylinder head 

NOTE: Make sure to tighten the bolts in the following three stages.
4. Tighten the RH 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 4: Tightening RH Bolts In Sequence

     Courtesy of FORD MOTOR CO.

   All cylinder heads 

5. Remove the special tools from both ends of the cylinder head.
   Fig 5: Removing Special Tools From Both Ends Of Cylinder Head

   Courtesy of FORD MOTOR CO.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Fig 6: Installing Hydraulic Lash Adjusters In Locations
Courtesy of FORD MOTOR CO.
6. Install the hydraulic lash adjusters in their original locations.

   RH cylinder head 

7. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
   Fig 7: Tightening Nuts In Sequence

   Courtesy of FORD MOTOR CO.

   LH cylinder head 

NOTE: Lubricate the O-ring seal with clean engine oil.
8. Install the oil level indicator tube.
   • Install a new O-ring seal on the oil level indicator tube.
   • Install the oil level indicator tube.
   • Install the bolt.
     Fig 8: Installing Oil Level Indicator Tube

     Courtesy of FORD MOTOR CO.
9. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
   Fig 9: Installing LH Exhaust Manifold And Exhaust Manifold Gaskets

   Courtesy of FORD MOTOR CO.

   All cylinder heads 

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
Fig 10: Compressing Tensioner Plunger, Using Vise
Courtesy of FORD MOTOR CO.
10. Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 11: Installing Retaining Clip On Tensioner

    Courtesy 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: Removing Tensioner From Vise

    Courtesy of FORD MOTOR CO.
14. Install the timing chain guides.
    Fig 13: Installing Timing Chain Guides

    Courtesy of FORD MOTOR CO.
15. Pre-position 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 Mark Position

       Courtesy of FORD MOTOR CO.
CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur.
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 Using Special Tool
Courtesy 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 Facing Position

    Courtesy 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 (Marked) Link On Chain

    Courtesy of FORD MOTOR CO.
NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Fig 18: Positioning Timing Chain On Camshaft Sprocket With Camshaft Sprocket Timing Mark
Courtesy 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.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Fig 19: Installing LH Timing Chain Tensioner
Courtesy 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

    Courtesy 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 sprocket with the single copper (marked) chain link.
    Fig 21: Aligning Timing Mark On Sprocket With Single Copper (Marked) Chain Link

    Courtesy of FORD MOTOR CO.
NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
Fig 22: Positioning RH Timing Chain On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
24. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 23: Installing RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
26. Remove the retaining clip from the RH timing chain tensioner.
    Fig 24: Removing Retaining Clip From RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
27. As a post-check, verify correct alignment of all timing marks.
    Fig 25: Identifying Alignment Of All Timing Marks

    Courtesy of FORD MOTOR CO.
28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 26: Identifying Timing Marks Alignment Position

    Courtesy of FORD MOTOR CO.
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: Compressing Valve Spring

       Courtesy of FORD MOTOR CO.
30. Remove the special tool.
    Fig 28: Removing Special Tool

    Courtesy of FORD MOTOR CO.
CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.
31. Install the eight spark plugs.
    • Tighten the spark plugs to 18 Nm (13 lb-ft).
32. Install the crankshaft sensor ring on the crankshaft.
    Fig 29: Installing Crankshaft Sensor Ring On Crankshaft

    Courtesy of FORD MOTOR CO.
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 30: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
Courtesy of FORD MOTOR CO.
33. 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.
34. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 31: Installing Engine Front Cover Gasket On Engine Front Cover

    Courtesy of FORD MOTOR CO.
35. Tighten the engine front cover fasteners in sequence in three stages.
    1. Stage 1: Tighten fasteners 1 through 7 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 32: Tightening Engine Front Cover Fasteners In Sequence

       Courtesy of FORD MOTOR CO.
36. Loosely install the bolts, then tighten the bolts in two stages, in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
      Fig 33: Tightening Bolts In Sequence

      Courtesy of FORD MOTOR CO.
37. Position the belt idler pulley and install the bolt.
    Fig 34: Installing Bolt

    Courtesy of FORD MOTOR CO.
38. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 35: Lubricating Engine Front Cover And Crankshaft Front Seal Inner Lip

    Courtesy of FORD MOTOR CO.
39. Use the special tools to install the crankshaft front seal into the engine front cover.
    Fig 36: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool

    Courtesy of FORD MOTOR CO.
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 37: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
Courtesy of FORD MOTOR CO.
40. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
41. Use the special tool to install the crankshaft pulley.
    Fig 38: Installing Crankshaft Pulley Using Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.
42. Tighten the new crankshaft pulley 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 39: Tightening Crankshaft Pulley Bolt

      Courtesy of FORD MOTOR CO.
43. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 40: Installing Bolts

    Courtesy of FORD MOTOR CO.
44. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    Fig 41: Installing Valve Cover Gasket

    Courtesy of FORD MOTOR CO.
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 42: Applying Silicone Gasket And Sealant In Front Cover
Courtesy of FORD MOTOR CO.
45. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
46. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 43: Positioning LH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.
47. Tighten the bolts in the sequence shown.
    Fig 44: Tightening Bolts In Sequence

    Courtesy of FORD MOTOR CO.
48. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    Fig 45: Installing Valve Cover Gasket

    Courtesy of FORD MOTOR CO.
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: Applying Silicone Gasket And Sealant In Engine Front Cover
Courtesy 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 RH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 47: Positioning RH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.
51. Tighten the bolts in the sequence shown.
    Fig 48: Tightening Bolts In Sequence

    Courtesy of FORD MOTOR CO.
52. Install the crankcase ventilation tube on the LH valve cover.
    Fig 49: Installing Crankcase Ventilation Tube On LH Valve Cover

    Courtesy of FORD MOTOR CO.
53. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
    Fig 50: Installing Positive Crankcase Ventilation (PCV) Valve And Hose In RH Valve Cover

    Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 51: Installing Radio Frequency Interference Capacitors
Courtesy of FORD MOTOR CO.
54. Install the radio frequency interference capacitors.
55. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
56. Install the bracket.
    Fig 52: Installing Bracket

    Courtesy of FORD MOTOR CO.

    Vehicles without A/C 

57. Connect the CKP sensor electrical connector.
    Fig 53: Connecting CKP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.

    All cylinder heads 

58. Connect the oil pressure switch electrical connector.
    Fig 54: Connecting Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
59. Connect the knock sensor electrical connector.
    Fig 55: Connecting Knock Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
60. Connect the RH radio frequency interference capacitor electrical connector.
    Fig 56: Connecting RH Radio Frequency Interference Capacitor Electrical Connector

    Courtesy of FORD MOTOR CO.
61. Connect the CMP sensor electrical connector.
    Fig 57: Connecting CMP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
62. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
    Fig 58: Connecting LH Radio Frequency Interference Capacitor And CHT Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
Fig 59: Installing Cylinder Block Drain Plugs
Courtesy of FORD MOTOR CO.
63. Install the cylinder block drain plugs.
64. Install the RH engine mount.
    • Tighten the bolts to 63 Nm (46 lb-ft).
65. Install the special tool.
    Fig 60: Installing Special Tool

    Courtesy of FORD MOTOR CO.
66. Install the special tool.
    Fig 61: Installing Special Tool

    Courtesy of FORD MOTOR CO.
67. Install the special tool and remove the engine from the work stand.
    Fig 62: Removing Engine From Work Stand

    Courtesy of FORD MOTOR CO.
68. Lower the engine onto wooden blocks.
69. Remove the special tool.
    Fig 63: Removing Special Tool

    Courtesy of FORD MOTOR CO.
70. Remove the special tool.
    Fig 64: Removing Special Tool

    Courtesy of FORD MOTOR CO.
71. Install the special tool and raise the engine.
    Fig 65: Installing Special Tool And Raising Engine

    Courtesy of FORD MOTOR CO.
72. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence shown.
    Fig 66: Tightening Bolts In Sequence

    Courtesy of FORD MOTOR CO.
73. Install the engine. Refer to ENGINE .