Cylinder Head: Installation

Both cylinder heads 

NOTE: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Head  in the Removal portion of this article.
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
NOTE: 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 in illustration, LH head gasket similar.
1. Install the new head gaskets over the dowel pins.
Fig 1: Head Gasket & Dowel Pins
Courtesy of FORD MOTOR CO.
NOTE: 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.
NOTE: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Head  in the Removal portion of this article.
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
NOTE: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
NOTE: RH cylinder head shown in illustration, LH cylinder head similar.
2. Install the cylinder heads on the dowels and the head gasket. Loosely install new bolts.
Fig 2: Locating Cylinder Head
Courtesy of FORD MOTOR CO.
3. Tighten the cylinder head bolts in 6 stages, in the sequence shown in illustration.
   • Stage 1: Tighten to 40 Nm (30 lb-ft).
   • Stage 2: Tighten an additional 90 degrees (1/4 turn).
   • Stage 3: Loosen a minimum of one full turn (360 degrees).
   • Stage 4: Tighten to 40 Nm (30 lb-ft).
   • Stage 5: Tighten an additional 90 degrees (1/4 turn).
   • Stage 6: Tighten an additional 90 degrees (1/4 turn).
Fig 3: Cylinder Head Bolt Torque Sequence
Courtesy of FORD MOTOR CO.
4. Remove the Cylinder Head Remover/Installer from both ends of the cylinder head.
Fig 4: Identifying Special Tool (303-572)
Courtesy of FORD MOTOR CO.

LH cylinder head 

NOTE: Lubricate the O-ring seal with clean engine oil.
5. Install a new O-ring seal on the oil level indicator tube and install the oil level indicator tube and bolt.
   • Tighten to 10 Nm (89 lb-in).
Fig 5: Oil Level Indicator Tube Bolt
Courtesy of FORD MOTOR CO.
6. Install the 8 new LH exhaust manifold studs.
   • Tighten to 12 Nm (106 lb-in).
7. Install a new LH exhaust manifold gasket, the LH exhaust manifold and 8 new nuts.
   • Tighten to 20 Nm (177 lb-in) in the sequence shown in illustration.
Fig 6: Tightening Sequence
Courtesy of FORD MOTOR CO.

RH cylinder head 

8. Install the 8 new RH exhaust manifold studs.
   • Tighten to 12 Nm (106 lb-in).
9. Install a new RH exhaust manifold gasket, the RH exhaust manifold and 8 new nuts.
   • Tighten to 20 Nm (177 lb-in) in the sequence shown in illustration.
Fig 7: Tightening Sequence
Courtesy of FORD MOTOR CO.

Engines with ratcheting timing chain tensioners 

NOTE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
NOTE: LH shown in illustration, RH similar.
10. Compress each tensioner plunger, using an edge of a vise.
Fig 8: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
11. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
Fig 9: Pushing Back And Holding Ratchet Mechanism
Courtesy of FORD MOTOR CO.
12. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Fig 10: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
13. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
    • Remove the tensioner from the vise.
Fig 11: Installing Paper Clip Into Tensioner Housing
Courtesy of FORD MOTOR CO.

Engines with non-ratcheting timing chain tensioners 

NOTE: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body or permanent compression of the seal bead will require replacement of the tensioner or damage to the engine may occur.
14. Inspect the RH and LH timing chain tensioners.
    • Install new tensioners as necessary.
NOTE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTE: LH shown in illustration, RH similar.
15. Compress each tensioner plunger, using an edge of a vise.
Fig 12: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
16. Install a Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.
Fig 13: Identifying Retaining Clip On Tensioner
Courtesy of FORD MOTOR CO.

Both cylinder heads 

17. If the colored links are not visible, mark one link on one end and one link on the other end and use as timing marks.
Fig 14: Identifying Timing Chain Copper Links
Courtesy of FORD MOTOR CO.
18. Using the Crankshaft Holding Tool, position the crankshaft.
    • Remove the special tool after crankshaft positioning.
Fig 15: Identifying Crankshaft Position
Courtesy of FORD MOTOR CO.
19. Install the crankshaft sprocket, making sure the flange faces forward.
Fig 16: Identifying Crankshaft Sprocket Flange
Courtesy of FORD MOTOR CO.
20. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts to 10 Nm (89 lb-in).
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts to 10 Nm (89 lb-in).
Fig 17: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.
21. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
Fig 18: Identifying LH And RH Camshaft Timing Mark Position
Courtesy of FORD MOTOR CO.
22. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
Fig 19: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
23. Install the LH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
Fig 20: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
24. Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
Fig 21: Positioning LH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
25. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
Fig 22: Identifying Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
26. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
Fig 23: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
27. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
Fig 24: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
28. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
Fig 25: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
29. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
Fig 26: Identifying Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
30. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
Fig 27: Identifying Copper (Marked) Chain Links And Dots On Crankshaft Sprockets And Camshaft Sprockets
Courtesy of FORD MOTOR CO.
31. Rotate the camshaft until the lobe is in the upward position.
Fig 28: Positioning Camshaft Lobe Up
Courtesy of FORD MOTOR CO.
32. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
Fig 29: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
33. Install the 16 hydraulic lash adjusters in their original locations (4 shown in illustration).
Fig 30: Lash Adjusters
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.
34. Install the camshaft roller follower.
    1. Install the Valve Spring Compressor.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original location.
Fig 31: Installing Camshaft Roller Follower
Courtesy of FORD MOTOR CO.
35. Remove the Valve Spring Compressor Spacer.
Fig 32: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug.
36. Install all 8 spark plugs.
    • Tighten to 18 Nm (159 lb-in).
Fig 33: Spark Plug
Courtesy of FORD MOTOR CO.
37. Install the crankshaft sensor ring.
Fig 34: View Of Crankshaft Sensor Ring At Crankshaft
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. Failure to follow this procedure can cause future oil leakage.
38. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
Fig 35: Applying Sealant At Head-To-Block Surface & The Oil Pan-To-Block Surface
Courtesy of FORD MOTOR CO.
39. 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 36: Installing Engine Front Cover Gasket On Engine Front Cover
Courtesy of FORD MOTOR CO.
40. Tighten the front cover fasteners in the sequence shown in illustration to 25 Nm (18 lb-ft).

    Item	Part Number	Description
    1	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    2	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    3	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    4	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    5	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    6	W706508	Stud, hex-head pilot, M8 x 1.25 x 50 - M6 x 1 x 10
    7	N808586	Stud, washer hex-head pilot, M8 x 1.25 - M6 x 1.0 x 86.35
    8	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    9	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    10	N806177	Bolt, hex flange head pilot, M8 x 1.25 x 53
    11	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
    12	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
    13	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
    14	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
    15	N806300	Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1

Fig 37: Engine Front Cover Fastener Removal/Tightening Sequence
Courtesy of FORD MOTOR CO.
41. Loosely install the 4 bolts, then tighten in 2 stages in the sequence shown in illustration.
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
Fig 38: Identifying Bolts
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
42. Install the RH and LH engine mounts and the bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 39: Engine Mount Bolts
Courtesy of FORD MOTOR CO.
43. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
Fig 40: Locating Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
44. Using the Crankshaft Front Oil Seal Installer, Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the front oil seal.
Fig 41: 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. Failure to follow this procedure can cause future oil leakage.
45. Apply sealant to the Woodruff key slot on the crankshaft pulley.
Fig 42: Woodruff Key Slot (With Specifications)
Courtesy of FORD MOTOR CO.
46. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
Fig 43: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
NOTE: Use the Strap Wrench to hold the crankshaft pulley.
47. Install the bolt and washer and tighten the crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Rotate an additional 90 degrees (1/4 turn).
Fig 44: Holding Crankshaft Pulley Using Special Tool (303-D055)
Courtesy of FORD MOTOR CO.
48. Position the coolant pump pulley on the coolant pump and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 45: Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
49. Install the accessory drive belt idler pulley and bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 46: Accessory Drive Belt Idler Pulley Bolt
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. Failure to follow this procedure can cause future oil leakage.
50. Apply sealant in 2 places where the engine front cover meets the cylinder head.
Fig 47: Applying Sealant At Engine Front Cover/Cylinder Head Surface
Courtesy of FORD MOTOR CO.
51. Install the new valve cover gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown in illustration.
    • Tighten to 10 Nm (89 lb-in).
Fig 48: Tightening Sequence
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. Failure to follow this procedure can cause future oil leakage.
52. Apply sealant in 2 places where the engine front cover meets the cylinder head.
Fig 49: Applying Sealant At Engine Front Cover/Cylinder Head Surface (With Specifications)
Courtesy of FORD MOTOR CO.
53. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown in illustration.
    • Tighten to 10 Nm (89 lb-in).
Fig 50: Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine coolant.
54. Inspect the O-ring seals. Install new seals, if necessary.
Fig 51: O-Ring Seals
Courtesy of FORD MOTOR CO.
55. Install the coolant bypass tube.
Fig 52: Coolant Bypass Tube
Courtesy of FORD MOTOR CO.
56. Install the ground strap on the rear of the RH cylinder head.
    1. Install the stud bolt and tighten to 25 Nm (18 lb-ft).
    2. Install the ground strap.
    3. Install the retaining nut and tighten to 10 Nm (89 lb-in).
Fig 53: Ground Strap, Stud & Nut
Courtesy of FORD MOTOR CO.
NOTE: Align the gasket locator tabs to slots in cylinder head.
57. Install the new intake manifold gaskets, intake manifold and hand-tighten the bolts at the locations shown in illustration.
Fig 54: Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
58. Install the 8 ignition coils and tighten the 8 bolts (4 shown in illustration).
    • Tighten to 6 Nm (53 lb-in).
Fig 55: Ignition Coils & Bolts
Courtesy of FORD MOTOR CO.
59. Install the intake manifold bracket and loosely install the bolt and the stud.
Fig 56: Intake Manifold Crash Bracket Bolt
Courtesy of FORD MOTOR CO.
60. Install the thermostat.
Fig 57: Thermostat
Courtesy of FORD MOTOR CO.
61. Install the coolant outlet adapter and loosely install the 2 bolts.
Fig 58: Coolant Outlet Adapter & Bolts
Courtesy of FORD MOTOR CO.
62. Tighten the bolts in the sequence shown in illustration.
    • Tighten to 25 Nm (18 lb-ft).
Fig 59: Intake Manifold Bolt Tightening Torque Sequence
Courtesy of FORD MOTOR CO.
63. Tighten the stud.
    • Tighten to 25 Nm (18 lb-ft).
Fig 60: Stud Bolt
Courtesy of FORD MOTOR CO.
64. Tighten the bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 61: Coolant Outlet Adapter & Bolts
Courtesy of FORD MOTOR CO.
65. Connect the EGR tube to the EGR valve.
    • Tighten to 43 Nm (32 lb-ft).
Fig 62: EGR Tube Nut At EGR
Courtesy of FORD MOTOR CO.
66. Connect the EGR tube-to-exhaust manifold connector.
    • Tighten to 43 Nm (32 lb-ft).
Fig 63: EGR Tube At Exhaust Manifold
Courtesy of FORD MOTOR CO.
67. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
68. Install the generator and bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 64: Generator & Bolts
Courtesy of FORD MOTOR CO.
69. Connect the throttle control and the Throttle Position (TP) sensor electrical connector.
Fig 65: Locating Throttle Control And Throttle Position (TP) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
70. Install the generator mounting bracket and bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 66: Generator Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
71. Attach the wire harness retainer and connect the generator electrical connector.
Fig 67: Electrical Connector And Wire Harness Retainer
Courtesy of FORD MOTOR CO.
72. Connect the electrical connector to the EGR vacuum regulator solenoid.
Fig 68: EGR Vacuum Regulator Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
73. Connect the crankcase ventilation tube.
Fig 69: Crankcase Ventilation Tube
Courtesy of FORD MOTOR CO.
74. Install the intake manifold shield and bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 70: Intake Manifold Shield
Courtesy of FORD MOTOR CO.
75. Connect the 8 fuel injector electrical connectors (4 shown in illustration).
Fig 71: Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
76. Connect the 8 ignition coil electrical connectors.
Fig 72: Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
77. Connect the Camshaft Position (CMP) sensor electrical connector.
Fig 73: Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
78. Connect the radio interference capacitor electrical connector.
Fig 74: Radio Ignition Interference Capacitor
Courtesy of FORD MOTOR CO.
79. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
Fig 75: Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
80. Install the battery cables and the bolt.
81. Install the Engine Lifting Bracket to the RH cylinder head.
Fig 76: Installing Special Tool To RH Cylinder Head
Courtesy of FORD MOTOR CO.
82. Install the Engine Lifting Bracket to the LH cylinder head.
Fig 77: Installing Special Tool To LH Cylinder Head
Courtesy of FORD MOTOR CO.
83. Using the Engine Lifting Bracket Set, remove the engine from the engine stand.
Fig 78: Mounting Engine On A Suitable Engine Stand
Courtesy of FORD MOTOR CO.
84. Install the engine/transmission spacer plate.
Fig 79: Engine-To-Transmission Spacer Plate
Courtesy of FORD MOTOR CO.
85. Position the flexplate and install the bolts in the sequence shown in illustration.
    • Tighten to 80 Nm (59 lb-ft).
Fig 80: Tightening Sequence
Courtesy of FORD MOTOR CO.
86. Install the engine. For additional information, refer to Engine  in the Installation portion of this article.