Cylinder Head: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance. If the original parts are being installed it is not necessary to check the valve clearance.

Refer to cylinder head. Refer to: Cylinder Head .
Clean and inspect the turbocharger mounting flange.

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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.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Make sure that the mating faces are clean and free of foreign material.

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

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Install the cylinder head gasket.

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NOTE: Note the routing of the KS (knock sensor) wiring before installation of the cylinder head.

Install the cylinder head.

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NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. Discard the camshaft bearing cap bolts.

NOTE: For cylinder heads with the camshafts partially installed.

NOTE: Discard the 8 camshaft bearing cap bolts.

If necessary, loosen the camshaft bearing cap bolts 1 turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts, the camshaft caps and the camshafts. Discard the camshaft bearing cap bolts.

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NOTE: Make sure that new bolts are installed.

NOTE: Make sure that no fluids are present in the cylinder head bolt threaded bores.

Install the new cylinder head bolts and tighten in sequence shown.

Torque: Stage 1: 44 lb.in (5 Nm), Stage 2: 133 lb.in (15 Nm), Stage 3: 26 lb.ft (35 Nm), Stage 4: 90 deg., Stage 5: 90 deg.

Fig 1: Cylinder Head Bolts Tightening Sequence
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Install a new mega cap O-ring seal.

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Install the crankcase vent oil drain tube.

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NOTE: The VCT bridge must be installed within 5 minutes of applying the gasket maker.

Apply a 2 mm bead of flange sealant.

Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

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NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.

NOTE: Make sure that the camshafts and camshaft bearing caps are installed in their original locations or damage to the engine may occur.

NOTE: Make sure that the mating faces are clean and free of foreign material.

NOTE: Apply clean engine oil to the bearing surfaces of the camshafts, camshaft bearing caps and the VCT bridge.

NOTE: Make sure that new bolts are installed.
- Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head.
  Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
  
  Torque: Stage 1: Tighten bolts 1 through 16 to: : 62 lb.in (7 Nm) Stage 2: Tighten bolts 17 through 20 to: : 89 lb.in (10 Nm) Stage 3: Tighten bolts 1 through 16 an additional: : 45 deg. | Stage 4: Tighten bolts 17 and 18 an additional: : 70 deg. | Stage 5: Tighten bolts 19 and 20 an additional: : 53 deg.
Fig 2: Cylinder Head Bolts Tightening Sequence
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Install the camshaft seals. Refer to: Camshaft Seal .
NOTE: Make sure that the components are installed to the position noted before removal.

Position the timing belt on the VCT units.

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WARNING: The tensioner is under spring tension. Be careful when handling the tensioner. Failure to follow this instruction may result in personal injury.
1. Verify that the timing belt is properly aligned.
2. Remove the holding pin.
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1. Make sure that the components are installed to the position noted before removal.
2. Remove Special Service Tool: 303-1556 Locking Tool, Timing Belt.
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Remove Special Service Tool: 303-748 Locking Tool, Crankshaft.

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Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit.

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NOTE: There are different length of bolts noted in disassembly.

Install the engine mount bracket and the bolts.

Torque: 41 lb.ft (55 Nm)

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Install the engine front cover.

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Install the engine front cover bolts.
Torque: 89 lb.in (10 Nm)

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Close the engine front cover side panel and install the stud bolt.
Torque: 89 lb.in (10 Nm)

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Install the bracket, the nut and the bolt.
Torque: Bolt : 17 lb.ft (23 Nm) Nut : 62 lb.in (7 Nm)

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Install the engine mount stud finger tight.

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Position back the generator and install the stud.
Torque: 89 lb.in (10 Nm)

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1. Install the bracket, if equipped and the upper generator stud bolt.
  Torque: 35 lb.ft (47 Nm)
2. Install the generator nut.
  Torque: 35 lb.ft (47 Nm)
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Tighten the lower generator bolt.
Torque: 35 lb.ft (47 Nm)

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NOTE: Only tighten the bolts finger tight at this stage.

Install the coolant pump pulley and the bolts.

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Install the following items:
1. Install the accessory drive belt. Refer to: Accessory Drive Belt .
2. Install the engine mount. Refer to: Engine Mount .
Install the intake manifold bolt.
Torque: 159 lb.in (18 Nm)

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Position back the crankcase vent oil separator inlet pipe and install the bolt.
Torque: 35 lb.in (4 Nm)

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Install and connect the engine vent hose. Use the General Equipment: Hose Clamp Remover/Installer

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NOTE: Hand start the intake manifold bolt first.

Install the intake manifold bracket and bolts.

Torque: Cylinder head bolt : 159 lb.in (18 Nm) Intake manifold bolt : 89 lb.in (10 Nm)

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Install the TB (throttle body). Refer to: Throttle Body .
Lubricate the coolant outlet O-ring seal with clean coolant.
Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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- Position back the coolant outlet and install the stud.
  Torque: 44 lb.in (5 Nm)
- Install the nut.
  Torque: 159 lb.in (18 Nm)
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Position back and connect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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Install the new TC mounting gasket and the studs.
Torque: 89 lb.in (10 Nm)

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Install the TC nuts.
Torque: Stage 1: : 62 lb.in (7 Nm) Stage 2: : 124 lb.in (14 Nm) Stage 3: : 17 lb.ft (23 Nm)

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Lubricate the new O-ring seals with clean engine oil.
Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

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Install the new TC oil supply tube assembly.
Torque: 19 lb.ft (26 Nm)

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NOTE: When installing the oil supply tube, the spigot on the oil supply tube must be fully engaged to the cylinder head with both O-rings inserted before the fastener is tightened.

Position the oil supply tube and install the bolt.

Torque: 89 lb.in (10 Nm)

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Install the turbocharger heat shield and the bolts.
Torque: 89 lb.in (10 Nm)

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Install the new turbocharger coolant tube O-ring seals and lubricate with clean engine coolant.
Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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Position back the TC coolant tubes and install the bolt.
Torque: 89 lb.in (10 Nm)

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1. Install the turbocharger coolant tube bolt.
  Torque: 17 lb.ft (23 Nm)
2. Install the turbocharger coolant tube bolt.
  Torque: 97 lb.in (11 Nm)
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Connect the retainer to the coolant tube bracket.

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Attach the wiring harness retainers.

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Position back the coolant hoses and connect the quick release couplings.

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Connect the TB (throttle body) electrical connector and the wiring harness retainer.

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1. Connect and attach the KS electrical connector.
2. Connect and attach the KS electrical connector.
3. Position back and connect the coolant hose.
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Connect the IAT sensor electrical connector and the wire harness retainer.

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Position back the wiring harness and attach the wiring harness retainer. Install the wiring harness bolt.
Torque: 89 lb.in (10 Nm)

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Connect the electrical connector and attach the wiring harness retainer.

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Connect the PCM electrical connector.

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Install the following items:
1. Install the brake vacuum pump. Refer to: Brake Vacuum Pump - 1.5L EcoBoost (118kW/160PS) - I4 .
2. Install the High-Pressure fuel pump drive unit. Refer to: High-Pressure Fuel Pump Drive Unit .
Connect the CHT sensor electrical connector and install the cover.

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- Connect the electrical connectors to the bracket.
- Connect the turbocharger vacuum hose and retainers. Use the General Equipment: Hose Clamp Remover/Installer
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If equipped, install the heat shield and the retainers.

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Connect the CKP sensor electrical connector and the wire harness retainers.

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Tighten the coolant pump pulley bolts.
Torque: 18 lb.ft (24 Nm)

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Install the engine plug bolt.
Torque: 177 lb.in (20 Nm)

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Position the halfshaft bearing bracket and install the bolts.
Torque: 35 lb.ft (48 Nm)

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1. Install the halfshaft bearing bracket strap and the retaining nuts.
  Torque: 44 lb.in (5 Nm)
2. Tighten the nut.
  Torque: 18 lb.ft (25 Nm)
3. Tighten the nut.
  Torque: 18 lb.ft (25 Nm)
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Remove and discard the engine oil filter. Use the General Equipment: Oil Drain Equipment. Use the General Equipment: Strap Wrench

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Remove the drain plug, drain engine oil and install drain plug. Use the General Equipment: Oil Drain Equipment
Torque: 21 lb.ft (28 Nm)

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NOTE: Lubricate the new engine oil filter with clean engine oil.

Lubricate the O-ring seal and install the new engine oil filter.

Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

Torque: 133 lb.in (15 Nm)

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Install the underbody shield and the retainers.

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1. Install the EVAP canister purge valve. Refer to: Evaporative Emission Canister Purge Valve .
2. Install the CAC inlet pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
Fill the engine with clean engine oil.
Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

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Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
Fill and bleed the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .