Cylinder Head: Installation
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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.
Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
Use the General Equipment: Plastic Scraper
Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B
- Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
- Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
- Apply a 6 mm bead of silicone sealant.
Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- Install a new cylinder head gasket.
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NOTE: The cylinder head bolts are torque-to-yield and must not be re Use d. New cylinder head bolts must be installed.
Install the cylinder head and the bolts. Tighten in sequence displayed in 5 stages.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-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 °
- Connect the coolant hose.
Use the General Equipment: Hose Clamp Remover/Installer
- Connect the EGR valve coolant hose.
Use the General Equipment: Hose Clamp Remover/Installer
- Connect the coolant hoses.
Use the General Equipment: Hose Clamp Remover/Installer
- Position the coolant hose clip.
- Connect the EGR electrical connector.
- Install the EGR tube.
Torque: 41 lb.ft (55 Nm)
- Lubricate with clean engine oil and install the valve tappets.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- Install the following items:
- Install the camshafts. Refer to: Camshafts .
- Install the fuel injectors. Refer to: Fuel Injectors .
- Install the intake manifold. Refer to: Intake Manifold .
- Install the air cleaner. Refer to: Air Cleaner .
- Install the new exhaust manifold studs.
Torque: 150 lb.in (17 Nm)
- Install the new exhaust manifold gasket.
- Position the exhaust manifold and install the nuts.
Torque: 41 lb.ft (55 Nm)
- Install the bolts for the exhaust manifold.
Torque: 18 lb.ft (25 Nm)
- Install a new exhaust system gasket.
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- Position the exhaust system.
- Install the new nuts.
Torque: 35 lb.ft (48 Nm)
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NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.
Remove the exhaust flexible pipe support.
- Install the exhaust manifold bracket bolts.
Torque: 18 lb.ft (25 Nm)
- Install the underbody shield and the retainers.
- Install the exhaust manifold heat shield and the bolts.
Torque: 89 lb.in (10 Nm)
- Attach the wire harness retainers, connect the HO2S and CMS electrical connectors.
- Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- Fill the engine with clean engine oil.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- Fill and bleed the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .