Cylinder Head: Installation

Both sides 

1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
2. Position the cylinder head gaskets on the block.
Fig 1: Locating Cylinder Head Gaskets On Block
Courtesy of FORD MOTOR CO.

RH side 

NOTE: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
3. Position the RH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
   • Stage 1: Tighten to 12 Nm (106 lb-in).
   • Stage 2: Tighten to 25 Nm (18 lb-ft).
Fig 2: Identifying Tightening Sequence Of 12-MM Bolts
Courtesy of FORD MOTOR CO.
4. Install 2 new M8 bolts.
   • Tighten to 32 Nm (24 lb-ft).
Fig 3: Locating 8-Mm Bolts
Courtesy of FORD MOTOR CO.
5. Tighten the 8 M12 bolts in the sequence shown in 2 stages.
   • Stage 1: Tighten 90 degrees.
   • Stage 2: Tighten an additional 90 degrees.
Fig 4: Identifying Tightening Sequence Of 12-MM Bolts
Courtesy of FORD MOTOR CO.
NOTE: The camshaft gear must turn freely on the camshaft. Do not tighten the bolt at this time.
NOTE: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
6. Remove the rubber band, position the camshaft sprocket and chain. Loosely install the bolt.
Fig 5: Locating Camshaft Sprocket & Bolt
Courtesy of FORD MOTOR CO.
7. Install the RH side cassette bolt.
   • Tighten to 12 Nm (106 lb-in).
Fig 6: Locating RH Side Cassette Bolt
Courtesy of FORD MOTOR CO.

LH side 

NOTE: To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.
NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
8. Position the LH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
   • Stage 1: Tighten to 12 Nm (106 lb-in).
   • Stage 2: Tighten to 25 Nm (18 lb-ft).
Fig 7: Identifying Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
9. Install 2 new M8 bolts.
   • Tighten to 32 Nm (24 lb-ft).
Fig 8: Locating 8-Mm Bolts
Courtesy of FORD MOTOR CO.
10. Tighten the 8 M12 bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten 90 degrees.
    • Stage 2: Tighten an additional 90 degrees.
Fig 9: Identifying Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: The camshaft gear must turn freely on the camshaft. Do not tighten the bolt at this time.
11. Remove the rubber band, position the camshaft sprocket and chain. Loosely install the bolt.
Fig 10: Locating Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
12. Install the LH side cassette bolt.
    • Tighten to 19 Nm (168 lb-in).
Fig 11: Locating Chain Guide Bolt
Courtesy of FORD MOTOR CO.

Both sides 

NOTE: LH side shown, RH side similar.
13. Install the 12 exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
Fig 12: Locating Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, RH side similar.
14. Position new gaskets and the exhaust manifolds. Install the 12 new nuts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 13: Locating Exhaust Manifolds, Gaskets & Nuts
Courtesy of FORD MOTOR CO.
NOTE: Apply dielectric compound to the inside of the spark plug wire boots.
15. Connect the 6 spark plug wires to the spark plugs.
Fig 14: Locating Spark Plug Wires
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, RH side similar.
16. Install the 4 new catalytic converter-to-exhaust manifold nuts.
    • Tighten to 45 Nm (33 lb-ft).
Fig 15: Locating Catalytic Converter-To-Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new O-ring seals with clean engine oil.
17. Install the 6 fuel injectors.
    • Install new O-ring seals on the injectors.
    • Install the injectors.
18. Position the fuel rail and injectors and install the 4 bolts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 16: Locating Fuel Rail And Injectors Bolts
Courtesy of FORD MOTOR CO.
NOTE: The LH and RH camshafts must be retimed when either camshaft is disturbed.
19. Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
NOTE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crank sensor speed wheel and incorrect timing to the engine.
NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
20. Install the Crankshaft TDC Timing Tool.
Fig 17: Identifying Special Tool (303-573)
Courtesy of FORD MOTOR CO.
NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
21. Install the Camshaft Sprocket Holding Tool and Adapter on the rear of the RH cylinder head.
Fig 18: Locating Clamp Bolts & Special Tools (303-564, 303-578)
Courtesy of FORD MOTOR CO.
NOTE: The camshaft timing slots are off-center.
22. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Camshaft Holding Tool and Adapter, and install the Camshaft Holding Tool and Adapters on the front of the RH cylinder head.
Fig 19: Identifying Special Tools (303-576, 303-577)
Courtesy of FORD MOTOR CO.
23. Tighten the 2 top Camshaft Sprocket Holding Tool clamp bolts to 10 Nm (89 lb-in).
Fig 20: Locating Top Camshaft Sprocket Holding Tool Clamp Bolts
Courtesy of FORD MOTOR CO.
24. Install the Timing Chain Tensioner.
Fig 21: Identifying Special Tool (303-571)
Courtesy of FORD MOTOR CO.
NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt.
25. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt to 85 Nm (63 lb-ft).
Fig 22: Identifying Special Tool (303-575)
Courtesy of FORD MOTOR CO.
26. Install a new washer and the RH camshaft tensioner.
    • Tighten to 44 Nm (32 lb-ft).
Fig 23: Locating Hydraulic Camshaft Tensioner Bolt
Courtesy of FORD MOTOR CO.
NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
27. Install the Camshaft Sprocket Holding Tool and Adapter on the front of the LH cylinder head.
Fig 24: Identifying Special Holding Tool
Courtesy of FORD MOTOR CO.
NOTE: The camshaft timing slots are off-center.
28. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Adapters, and install the Camshaft Holding Tool and Adapter on the rear of the LH cylinder head.
Fig 25: Identifying Special Tools (303-576, 303-577)
Courtesy of FORD MOTOR CO.
29. Install the Timing Chain Tensioner.
Fig 26: Identifying Special Tool (303-571)
Courtesy of FORD MOTOR CO.
30. Tighten the bolts.
    1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in).
    2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).
Fig 27: Tightening Camshaft Sprocket Holding Tool Top Clamp Bolts
Courtesy of FORD MOTOR CO.
31. Install a new washer and the LH camshaft tensioner.
    • Tighten to 44 Nm (32 lb-ft).
Fig 28: Locating Camshaft Tensioner
Courtesy of FORD MOTOR CO.

LH side 

32. Position the ground strap and install the bolt.
    • Tighten to 40 Nm (30 lb-ft).
    • Attach the wiring harness retainer to the backside of the cylinder head.
Fig 29: Locating Ground Strap Bolt
Courtesy of FORD MOTOR CO.
33. Position the starter motor wiring retainer bracket and install the bolt.
    • Tighten to 40 Nm (30 lb-ft).
Fig 30: Locating Starter Motor Wiring Retainer Bracket Bolt
Courtesy of FORD MOTOR CO.
34. Position the FEAD bracket and A/C compressor. Install the 3 bolts and the nut.
    • Tighten to 48 Nm (35 lb-ft).
Fig 31: Locating FEAD Bracket And A/C Compressor Bracket Bolts
Courtesy of FORD MOTOR CO.
35. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 32: Locating Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
36. Position the power steering pump pulley and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 33: Locating Power Steering Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
37. Attach PSP tube bracket to the crossmember and install the bolt.
    • Tighten to 11 Nm (97 lb-in).
Fig 34: Locating PSP Tube Bracket Bolt
Courtesy of FORD MOTOR CO.
38. Attach the power steering supply hose bracket to the FEAD bracket and install the bolt.
    • Tighten to 11 Nm (97 lb-in).
Fig 35: Locating Power Steering Supply Hose Bracket Bolt
Courtesy of FORD MOTOR CO.
39. Position the ground strap and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 36: Locating Ground Strap Stud Bolt
Courtesy of FORD MOTOR CO.
40. Install the oil level indicator tube and bolt.
    • Tighten to 11 Nm (97 lb-in).
Fig 37: Locating Oil Level Indicator Tube And Bolt
Courtesy of FORD MOTOR CO.

RH side 

NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary.
41. Position the thermostat housing and install the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
Fig 38: Locating Thermostat Housing
Courtesy of FORD MOTOR CO.
42. Position the coolant bypass hose clamp and connect the ECT sensor electrical connector.
Fig 39: Locating Coolant Bypass Hose Clamp
Courtesy of FORD MOTOR CO.
43. Install the upper radiator hose.
Fig 40: Locating Upper Radiator Hose Clamp
Courtesy of FORD MOTOR CO.
44. Connect the heater hose to the thermostat housing.
Fig 41: Locating Heater Hose From Thermostat Housing
Courtesy of FORD MOTOR CO.
45. Position the generator mounting bracket assembly and install the 2 bolts and the nut.
    • Tighten to 47 Nm (35 lb-ft).
Fig 42: Locating Generator Mounting Bracket Assembly Bolts
Courtesy of FORD MOTOR CO.
46. Install the accessory drive belt tensioner and bolt.
    • Tighten to 47 Nm (35 lb-ft).
Fig 43: Locating Belt Tensioner Bolt
Courtesy of FORD MOTOR CO.
47. Connect the generator electrical connector. Position the B+ terminal and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    • Attach the pin-type retainer.
Fig 44: Locating Generator Electrical Connections Pin-Type Retainer
Courtesy of FORD MOTOR CO.
48. Install the 2 coolant tube bracket bolts.
    • Tighten the M12 bolt to 34 Nm (25 lb-ft).
    • Tighten the M8 bolt to 23 Nm (17 lb-ft).
Fig 45: Locating Coolant Tube Bracket Bolts
Courtesy of FORD MOTOR CO.

Both sides 

49. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
Fig 46: Rotating Accessory Drive Belt Tensioner
Courtesy of FORD MOTOR CO.
50. Install the hydraulic lash adjusters. For additional information, refer to Hydraulic Lash Adjuster .
51. Install the intake manifold. For additional information, refer to Intake Manifold .
52. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .