Cylinder Head - Plug-In Hybrid Electric Vehicle (PHEV): Installation

WARNING: This page is about a different car, the 2016 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

1.

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep.

NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.

Clean all mating surfaces.

Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

2.
- Refer to: Cylinder Head Distortion .
- Refer to: Cylinder Block Distortion .

3.

Material
: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

GFD70805

Courtesy of FORD MOTOR COMPANY

4.

GFD70806

Courtesy of FORD MOTOR COMPANY

5.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

Torque:

Stage 1: 62 lb.in (7 Nm)

Stage 2: 133 lb.in (15 Nm)

Stage 3: 33 lb.ft (45 Nm)

Stage 4: 90 °

Stage 5: 90 °

Fig 1: Cylinder Head (PHEV) Tightening Sequence

GFD70807

Courtesy of FORD MOTOR COMPANY

6.

Install Special Service Tool: 303-F072 Support Bar, Engine.

GFD70802

Courtesy of FORD MOTOR COMPANY

7.

Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block

GFD70801

Courtesy of FORD MOTOR COMPANY

8.

NOTE: Transmission removed from graphic for clarity.

GFD70800

Courtesy of FORD MOTOR COMPANY

9.

Refer to: Valve Tappets .

10.

Torque: 150 lb.in (17 Nm)

GFD70808

Courtesy of FORD MOTOR COMPANY

11.

Torque: 41 lb.ft (55 Nm)

GFD70818

Courtesy of FORD MOTOR COMPANY

12.

Torque: 89 lb.in (10 Nm)

GFD70815

Courtesy of FORD MOTOR COMPANY

13.

Torque: 18 lb.ft (25 Nm)

GFD70819

Courtesy of FORD MOTOR COMPANY

14.

Torque: 18 lb.ft (25 Nm)

GFD70796

Courtesy of FORD MOTOR COMPANY

15.

GFD70811

Courtesy of FORD MOTOR COMPANY

16.

Torque: 35 lb.ft (48 Nm)

GFD70812

Courtesy of FORD MOTOR COMPANY

17.

NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

GFD70817

Courtesy of FORD MOTOR COMPANY

18.

Refer to: Intake Manifold .

19.

Torque: 18 lb.ft (25 Nm)

GFD70789

Courtesy of FORD MOTOR COMPANY

20.

Refer to: Transmission Control Module (TCM) .

21.

WARNING: Be prepared to collect escaping fluid.

Use the General Equipment: Oil Drain Equipment

Torque: 20 lb.ft (27 Nm)

GFD70813

Courtesy of FORD MOTOR COMPANY

22.

Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
Torque:

Stage 1: 71 lb.in (8 Nm)

Stage 2: 180 °

GFD70814

Courtesy of FORD MOTOR COMPANY

23.

GFD70770

Courtesy of FORD MOTOR COMPANY

24.

Fill the engine with clean engine oil.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

25.
- Refer to: Battery Disconnect and Connect .
- Pressurize the fuel system. Refer to: Fuel System Pressure Release .
- Refer to: Cooling System Draining, Filling and Bleeding .
- Refer to: Cooling System Draining, Filling and Bleeding .