Cylinder Head: Assembly

All cylinder heads 

• 1.
  
  
  NOTE: If a spark plug is dropped, internal damage may result and the spark plug must be discarded. The use of a damaged spark plug may cause cylinder misfire resulting in engine damage.

  Install the spark plugs.

  Torque: 133 lb.in (15 Nm)

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• 2.
  
  
  NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.

  • 1.
    
    Install the Arbor on the fuel injector tips. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

  • 2.
    
    
    NOTE: Once the Teflon ® seal is installed on the Teflon ® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon ® seal.
    NOTE: Make sure that new lower fuel injector Teflon ® seals are installed.

    Install the new Teflon ® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon ® seals along the Arbor.

  • 3.
    
    Using the Pusher Tool, slide the Teflon ® seals off of the Teflon ® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

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• 3.
  
  
  NOTE: Make sure the Teflon ® seal is fully seated in the groove on the fuel injector before sizing the Teflon ® seal.

  • 1.
    
    Some Teflon ® seal massaging with your fingers before the Teflon ® seal sizer tool is installed will aid in installing the Teflon ® seal sizer tool.

  • 2.
    
    Position the Teflon ® seal sizer tool with the larger opening towards the Teflon ® seal. Push while turning the Teflon ® seal sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.

  • 3.
    
    Once the Teflon ® seal sizer tool is installed, check and make sure the Teflon ® seal is in the sizing portion of the Teflon ® seal sizer tool.

  • 4.
    
    After one minute, turn the Teflon ® seal sizer tool back 180 degrees and remove.

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• 4.
  
  
  NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.

  • 1.
    
    
    NOTE: The new the fuel injector support rings must be installed in the correct orientation with the larger surface facing up against the fuel injector O-ring seals. Improperly installed support rings may cause the fuel system to leak.

    Install the new the fuel injector support rings.

  • 2.
    
    
    NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the old O-ring seals.
    NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.

    Install the new fuel injector O-rings and lubricate with clean engine oil.

    Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

  • 3.
    
    Inspect the inlet stopper, if it is damaged or comes off discard the inlet stopper. The inlet stopper is not necessary for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.

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• 5.
  
  
  NOTE: Make sure that new fuel injector clips are installed.

  Install the new the fuel injector clips.

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• 6.
  
  
  NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.
  NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

  LH shown, RH similar. Install the fuel injectors to the fuel rail.

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• 7.
  
  
  NOTE: LH shown, RH similar.

  Connect the fuel injector electrical connectors.

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• 8.
  
  
  NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
  NOTE: LH shown, RH similar.

  Install the LH fuel rail, push down on the LH fuel rail above the injectors, then install and tighten the LH fuel rail bolts.

  Torque: 18 lb.ft (24 Nm)

Fig 1: LH Fuel Rail Tightening Sequence

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• 9.
  
  
  NOTE: LH shown, RH similar.

  Attach the wiring harness retainer.

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• 10.
  
  
  NOTE: Lubricate the new valve stem seal with clean engine oil.

  Install the new valve stem seal.

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 11.
  
  
  NOTE: Lubricate the valve stem with clean engine oil.

  Install the valve into the cylinder head.

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 12.
  
  
  • Using the special tools, install the spring, retainer and keys. Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor., 303-350 (T89P-6565-A) Compressor, Valve Spring., 303-1249 Valve Spring Compressor., 303-1418 Compressor, Valve Spring.
  • Repeat the previous steps for each of the remaining valves.

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RH cylinder heads 

• 13.
  
  
  NOTE: If the EOP switch is to be reused, apply thread sealant.

  Install the EOP switch.

  Material: Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)

  Torque: 24 lb.ft (33 Nm)

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LH cylinder heads 

• 14.
  
  
  NOTE: Do not reuse the CHT sensor, install a new sensor.

  Install a new CHT sensor.

  Torque: 106 lb.in (12 Nm)

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