Cylinder Head RH: Installation

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.

Using metal surface cleaner, clean the cylinder head sealing surfaces.

Fig 1: Cleaning Cylinder Head Sealing Surfaces
Courtesy of FORD MOTOR CO.
Check the cylinder head and cylinder block for flatness. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

NOTE: The "V" notch in the cylinder head gasket faces the front of the engine.

Fig 2: Positioning Cylinder Head Gasket

Courtesy of FORD MOTOR CO.

Position a new cylinder head gasket.
Position the cylinder head.

Fig 3: Positioning Cylinder Head
Courtesy of FORD MOTOR CO.
Install the bolts. Tighten the bolts in five stages in the sequence shown.
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Loosen the bolts one full turn.
- Stage 3: Tighten to 30 Nm (22 lb-ft).
- Stage 4: Rotate each bolt 90 degrees.
- Stage 5: Rotate each bolt an additional 90 degrees.
Fig 4: Tightening Sequence Of Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
Install the catalytic converter heat shield and wire harness ground connection.

Fig 5: Installing Catalytic Converter Heat Shield And Wire Harness Ground Connection
Courtesy of FORD MOTOR CO.
Position the wiring harness and install the harness locator.

Fig 6: Positioning Wiring Harness And Installing Harness Locator
Courtesy of FORD MOTOR CO.
Install the exhaust manifold. Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 22 Nm (16 lb-ft).
Fig 7: Tightening Sequence Of Exhaust Manifold Bolts
Courtesy of FORD MOTOR CO.
Tighten the exhaust manifold-to-catalytic converter bolts.

Fig 8: Tightening Exhaust Manifold-To-Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
Install the exhaust manifold heat shield.

Fig 9: Installing Exhaust Manifold Heat Shield
Courtesy of FORD MOTOR CO.
Install the EGR tube.

Fig 10: Installing EGR Tube
Courtesy of FORD MOTOR CO.
Reposition and connect the spark plug wires.

Fig 11: Connecting Spark Plug Wires
Courtesy of FORD MOTOR CO.
Connect the EVAP canister purge valve electrical connector.

Fig 12: Connecting EVAP Canister Purge Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the PCM electrical connector.

Fig 13: Connecting PCM Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the wire harness ground connections.

Fig 14: Connecting Wire Harness Ground Connections
Courtesy of FORD MOTOR CO.
Connect the HO2S electrical connector.

Fig 15: Connecting HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the CKP electrical connector.

Fig 16: Connecting CKP Electrical Connector
Courtesy of FORD MOTOR CO.
Install the lower intake manifold. For additional information, refer to LOWER INTAKE MANIFOLD .