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Home >> Ford >> 2004 >> Mustang Mach 1, Standard >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine - Mach1 4.6L (4V) >> Installation >> Cylinder Heads >> Both cylinder heads

Both cylinder heads

    CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. For additional information, 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: RH head gasket shown, LH head gasket similar.
    Fig 1: Installing Head Gasket Over Dowel Pins
    G03240867Courtesy of FORD MOTOR CO.
  1. Install the head gasket over the dowel pins.
    2. 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 the cylinder block must be clean. For additional information, 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.
    Fig 2: Installing Cylinder Head On Dowels And Head Gasket
    G03240868Courtesy of FORD MOTOR CO.
  2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.

    3. LH Cylinder Head 

  3. Tighten the bolts in six stages, in the sequence shown.
    • Stage 1: Tighten the bolts to 40 N.m (30 lb-ft).
    • Stage 2: Tighten the bolts an additional 90 degrees.
    • Stage 3: Loosen the bolts a minimum of one full turn.
    • Stage 4: Tighten to 40 N.m (30 lb-ft).
    • Stage 5: Tighten an additional 90 degrees.
    • Stage 6: Tighten an additional 90 degrees.
      Fig 3: LH Cylinder Head Bolts Tightening Sequence
      G03240869Courtesy of FORD MOTOR CO.

    4. RH Cylinder Head 

  4. Tighten the bolts in six stages in the sequence shown.
    • Stage 1: Tighten the bolts to 40 N.m (30 lb-ft).
    • Stage 2: Tighten the bolts an additional 90 degrees.
    • Stage 3: Loosen the bolts a minimum of one full turn.
    • Stage 4: Tighten to 40 N.m (30 lb-ft).
    • Stage 5: Tighten an additional 90 degrees.
    • Stage 6: Tighten an additional 90 degrees.
      Fig 4: RH Cylinder Head Bolts Tightening Sequence
      G03240870Courtesy of FORD MOTOR CO.

    5. Both Cylinder Heads 

    NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
    Fig 5: Installing Hydraulic Lash Adjusters
    G03240871Courtesy of FORD MOTOR CO.
  5. Install the hydraulic lash adjusters in their original locations.
    6. CAUTION: The timing chain procedures must be followed exactly or damage to the valves and pistons will result.
    CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    NOTE: LH shown, RH similar.
    Fig 6: Compressing Tensioner Plunger
    G03240872Courtesy of FORD MOTOR CO.
  6. Compress each tensioner plunger, using an edge of a vise.
  7. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
    Fig 7: Pushing Back And Hold Ratchet Mechanism
    G03240873Courtesy of FORD MOTOR CO.
  8. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 8: Pushing Ratchet Arm Back Into Tensioner Housing
    G03240874Courtesy of FORD MOTOR CO.
  9. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
    Fig 9: Installing Paper Clip Into Hole In Tensioner Housing
    G03240875Courtesy of FORD MOTOR CO.
  10. Remove the tensioner from the vise.
  11. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
    Fig 10: Identifying Timing Chain Copper Links/Marking Timing Chain Timing Marks
    G03240876Courtesy of FORD MOTOR CO.
  12. Install the timing chain guides.
    Fig 11: Installing Timing Chain Guides
    G03240877Courtesy of FORD MOTOR CO.
  13. Pre-position the camshafts.
    • Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position.
    • Rotate the RH camshaft timing sprocket until the timing mark is approximately at the 11 o'clock position.
      Fig 12: Aligning Camshaft Sprockets Timing Marks To Proper Location
      G03240878Courtesy of FORD MOTOR CO.
    14. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
    NOTE: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur.
  14. Using the special tool, position the crankshaft.
    15. Fig 13: Aligning Crankshaft To Proper Position
    G03240879Courtesy of FORD MOTOR CO.
  15. Install the crankshaft sprocket with the flange facing forward.
    Fig 14: Identifying Proper Crankshaft Sprocket Installation
    G03240880Courtesy of FORD MOTOR CO.
  16. Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
    Fig 15: Aligning LH (Inner) Timing Chain Copper (Marked) Link To Crankshaft Sprocket Timing Mark
    G03240881Courtesy of FORD MOTOR CO.
  17. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 16: Aligning LH (Inner) Timing Chain Copper (Marked) Link To Camshaft Sprocket Timing Mark
    G03240882Courtesy of FORD MOTOR CO.
    18. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 17: Installing LH Timing Chain Tensioner
    G03240883Courtesy of FORD MOTOR CO.
  18. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
  19. Remove the retaining clip from the LH timing chain tensioner.
    Fig 18: Removing Retaining Clip From LH Timing Chain Tensioner
    G03240884Courtesy of FORD MOTOR CO.
  20. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 19: Aligning RH (Outer) Timing Chain Copper (Marked) Link To Crankshaft Sprocket Timing Mark
    G03240885Courtesy of FORD MOTOR CO.
  21. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 20: Aligning RH (Outer) Timing Chain Copper (Marked) Link To Camshaft Sprocket Timing Mark
    G03240886Courtesy of FORD MOTOR CO.
  22. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 21: Positioning RH Timing Chain Tensioner
    G03240887Courtesy of FORD MOTOR CO.
  23. Remove the retaining clip from the RH timing chain tensioner.
    Fig 22: Removing Retaining Clip From RH Timing Chain Tensioner
    G03240888Courtesy of FORD MOTOR CO.
  24. As a post-check, verify correct alignment of all timing marks. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprockets.
    Fig 23: Verifying Proper Timing Mark Alignment
    G03240889Courtesy of FORD MOTOR CO.
  25. Position the piston of the cylinder being repaired at the bottom of the stroke and the camshaft lobe at the base circle.
  26. Using the special tool, compress the intake valve spring and install the roller followers in their original locations.
    Fig 24: Compressing Intake Valve Spring
    G03240890Courtesy of FORD MOTOR CO.
  27. Using the special tool, compress the exhaust valve spring and install the roller followers in their original locations.
    Fig 25: Compressing Exhaust Valve Spring
    G03240891Courtesy of FORD MOTOR CO.
  28. Repeat the above three steps to install all the roller followers.
  29. Position the crankshaft sensor ring on the crankshaft.
    Fig 26: Positioning Crankshaft Sensor Ring On Crankshaft
    G03240892Courtesy of FORD MOTOR CO.
    30. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to do this procedure can result in future oil leakage.
    Fig 27: Identifying Silicone Application Points - Engine Front Cover
    G03240893Courtesy of FORD MOTOR CO.
  30. Apply silicone gasket and sealant in the locations shown.
  31. Install the engine front cover and tighten the bolts in the sequence shown.
    Fig 28: Engine Front Cover Bolts Tightening Sequence/Bolt & Stud Identification
    G03240894Courtesy of FORD MOTOR CO.
  32. Loosely install the bolts, then tighten in two stages, in the sequence shown.
    • Tighten to 20 N.m (15 lb-ft).
    • Tighten an additional 60 degrees.
      Fig 29: Oil Pan Front Bolts Tightening Sequence
      G03240895Courtesy of FORD MOTOR CO.
    33. NOTE: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to do this procedure can result in future oil leakage.
    Fig 30: Identifying Silicone Application Points - Valve Covers
    G03240896Courtesy of FORD MOTOR CO.
  33. Apply silicone gasket and sealant in the locations shown.
    34. NOTE: The RH is shown, the LH is similar.
    Fig 31: Valve Covers Tightening Sequence
    G03240897Courtesy of FORD MOTOR CO.
  34. Install the valve covers and tighten the bolts in the sequence shown.
    35. NOTE: LH shown, RH similar.
    Fig 32: Installing Spark Plugs
    G03240898Courtesy of FORD MOTOR CO.
  35. Install the eight spark plugs.
  36. Install the belt idler pulleys.
    Fig 33: Installing Belt Idler Pulleys
    G03240899Courtesy of FORD MOTOR CO.
  37. Lubricate the front oil seal and the engine front cover with clean engine oil.
    Fig 34: Lubricating Front Oil Seal And Engine Front Cover
    G03240900Courtesy of FORD MOTOR CO.
  38. Using the special tool, install the front oil seal.
    Fig 35: Install Front Oil Seal
    G03240901Courtesy of FORD MOTOR CO.
    39. NOTE: If the crankshaft pulley is not installed within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to do this procedure can result in future oil leakage.
    Fig 36: Applying Silicone Gasket And Sealant To Woodruff Key On Crankshaft Pulley
    G03240902Courtesy of FORD MOTOR CO.
  39. Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
  40. Using the special tool, install the crankshaft pulley.
    Fig 37: Installing Crankshaft Pulley
    G03240903Courtesy of FORD MOTOR CO.
    41. NOTE: Use a suitable strap wrench (303-D055) or equivalent to hold the pulley while tightening the bolt.
  41. Install the crankshaft pulley and tighten the bolt in four stages.
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen the bolt one full turn.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
      Fig 38: Tightening Crankshaft Pulley Bolt
      G03240904Courtesy of FORD MOTOR CO.
  42. Install the coolant pump pulley and the bolts.
    Fig 39: Installing Coolant Pump Pulley
    G03240905Courtesy of FORD MOTOR CO.

    43. RH Cylinder Head 

  43. Install the RH exhaust manifold.
    • Install a new RH exhaust manifold gasket.
    • Install the RH exhaust manifold.
    • Tighten the nuts in the sequence shown.
      Fig 40: RH Exhaust Manifold Tightening Sequence
      G03240906Courtesy of FORD MOTOR CO.

    44. LH Cylinder Head 

  44. Inspect the O-ring seals and install new O-ring seals as necessary.
    Fig 41: Inspecting O-Ring Seals
    G03240907Courtesy of FORD MOTOR CO.
  45. Install the coolant bypass tube.
    1. Install the bypass tube.
    2. Install the nut and tighten to 25 N.m (18 lb-ft).
      Fig 42: Installing Coolant Bypass Tube
      G03240908Courtesy of FORD MOTOR CO.
    46. NOTE: Lubricate the O-ring with clean engine oil.
  46. Install the oil level indicator tube.
    • Install a new O-ring on the oil level indictor tube.
      Fig 43: Lubricating O-Ring With Clean Engine Oil
      G03240909Courtesy of FORD MOTOR CO.
  47. Install the LH exhaust manifold.
    • Install a new LH exhaust manifold gasket.
    • Install the LH exhaust manifold.
    • Tighten the nuts in the sequence shown.
      Fig 44: LH Exhaust Manifold Tightening Sequence
      G03240910Courtesy of FORD MOTOR CO.

    48. Both Cylinder Heads 

  48. Install the knock sensor harness.
    1. LH knock sensor connector.
    2. RH knock sensor connector.
    3. Engine control sensor wiring connector.
    4. Fuel injector connector.
    5. A/C compressor connector.
    6. Crankshaft position sensor connector.
      Fig 45: Installing Knock Sensor Harness
      G03240911Courtesy of FORD MOTOR CO.
  49. Install the lower intake manifold.
    • Position the gaskets.
    • Install the intake manifold and tighten the bolts in the sequence shown.
      Fig 46: Lower Intake Manifold Tightening Sequence
      G03240912Courtesy of FORD MOTOR CO.
    50. NOTE: Only three bolts are required for installation.
  50. Install the power steering pump bolts.
    • Position the power steering pump.
    • Install the bolts.
      Fig 47: Installing Power Steering Pump
      G03240913Courtesy of FORD MOTOR CO.
  51. Position the power steering reservoir and bracket, and install the bolts.
    Fig 48: Installing Power Steering Reservoir And Bracket
    G03240914Courtesy of FORD MOTOR CO.
  52. Install the generator.
    Fig 49: Installing Generator
    G03240915Courtesy of FORD MOTOR CO.
  53. Install the upper generator support bracket and water bypass tube.
    • Install the upper generator support bracket.
    • Inspect and install new O-ring seals if necessary.
    • Install the water bypass tube.
      Fig 50: Installing Upper Generator Support Bracket And Water Bypass Tube
      G03240916Courtesy of FORD MOTOR CO.
  54. Install the accessory drive belt.
    Fig 51: Installing Accessory Drive Belt
    G03240917Courtesy of FORD MOTOR CO.
  55. Connect the knock sensor jumper harness.
    Fig 52: Connecting Knock Sensor Jumper Harness
    G03240918Courtesy of FORD MOTOR CO.
  56. Install the eight ignition coils.
    Fig 53: Installing Ignition Coils
    G03240919Courtesy of FORD MOTOR CO.
  57. Connect the eight ignition coils.
    Fig 54: Connecting Ignition Coils
    G03240920Courtesy of FORD MOTOR CO.
  58. Connect the engine coolant temperature (ECT) sensor.
    Fig 55: Connecting Engine Coolant Temperature (ECT) Sensor
    G03240921Courtesy of FORD MOTOR CO.
  59. Connect the eight fuel injectors.
    Fig 56: Connecting Fuel Injectors
    G03240922Courtesy of FORD MOTOR CO.
  60. Install the RH ignition coil cover.
    Fig 57: Installing RH Ignition Coil Cover
    G03240923Courtesy of FORD MOTOR CO.
  61. Install the LH ignition coil cover.
    Fig 58: Installing LH Ignition Coil Cover
    G03240924Courtesy of FORD MOTOR CO.
    62. NOTE: The fastener at location five is a stud.
    Fig 59: Upper Intake Tightening Sequence
    G03240925Courtesy of FORD MOTOR CO.
  62. Install the gasket and the upper intake.
  63. Connect the throttle position (TP) sensor.
    Fig 60: Connecting Throttle Position (TP) Sensor
    G03240926Courtesy of FORD MOTOR CO.
  64. Connect the idle air control (IAC) valve.
    Fig 61: Connecting Idle Air Control (IAC) Valve
    G03240927Courtesy of FORD MOTOR CO.
  65. Connect the generator.
    Fig 62: Connecting Generator
    G03240928Courtesy of FORD MOTOR CO.
  66. Connect the fuel pressure sensor.
    Fig 63: Connecting Fuel Pressure Sensor
    G03240929Courtesy of FORD MOTOR CO.
  67. Connect the EGR tube to the exhaust manifold.
    Fig 64: Connecting EGR Tube To Exhaust Manifold
    G03240930Courtesy of FORD MOTOR CO.
  68. Connect the EGR tube to the EGR valve.
    Fig 65: Connecting EGR Tube To EGR Valve
    G03240931Courtesy of FORD MOTOR CO.
  69. Install the PCV tube and connect the electrical connector.
    Fig 66: Installing PCV Tube And Connect Electrical Connector
    G03240932Courtesy of FORD MOTOR CO.
  70. Connect the PCV valve tube to the upper intake manifold.
    Fig 67: Connecting PCV Valve Tube To Upper Intake Manifold
    G03240933Courtesy of FORD MOTOR CO.
  71. Install the RH engine mount and bolts.
    Fig 68: Installing RH Engine Mount
    G03240934Courtesy of FORD MOTOR CO.
  72. Install the special tools.
    Fig 69: Installing Engine Lifting Brackets
    G03240935Courtesy of FORD MOTOR CO.
  73. Remove the engine from the stand.
    Fig 70: Removing Engine From Stand
    G03240936Courtesy of FORD MOTOR CO.
  74. Install the engine/transmission spacer plate.
    Fig 71: Installing Engine/Transmission Spacer Plate
    G03240937Courtesy of FORD MOTOR CO.
  75. Install the flywheel or flexplate. Tighten in the sequence shown.
    Fig 72: Flywheel Or Flexplate Tightening Sequence
    G03240938Courtesy of FORD MOTOR CO.

    76. Manual Transmission Vehicles 

    NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol-based solvent so surfaces are free from oil. Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in the solvent.
  76. Position the clutch disc on the flywheel.
    • Using the special tool, align the clutch disc.
      Fig 73: Aligning Clutch Disc
      G03240939Courtesy of FORD MOTOR CO.
    77. NOTE: If reusing the clutch pressure plate, align the plate using the marks made during removal.
  77. Position the pressure plate and loosely install the bolts, then tighten in two stages in a cross pattern.
    • Stage 1: Tighten to 45 N.m (33 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
      Fig 74: Aligning Plate Using Marks Made During Removal
      G03240940Courtesy of FORD MOTOR CO.

    78. All Vehicles 

  78. Install the engine. For additional information, refer to ENGINE .
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