Cylinder Head: Assembly

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

NOTE: If installing the original valves, make sure the valves are installed in the same position from which they were removed.

Lubricate with clean engine oil and install the valve.

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NOTE: Use valve stem seal pliers (such as BeTooll HW0107 or equivalent).
- Lubricate the valve stem seal with clean engine oil.
- Use commercially available valve stem seal pliers to install the valve stem seal.
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NOTE: The intake and exhaust valve springs appear similar but are different parts and are not interchangeable. If the springs are to be reused they must be installed in their original location.

NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets. Check the seating of the valve collet.

Using the special tools, install the valve spring, valve spring retainer and the valve collet. Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor., 303-350 (T89P-6565-A) Compressor, Valve Spring., 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor., 303-1249 Valve Spring Compressor.

Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

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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: 106 lb.in (12 Nm)

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Install a new cylinder head cover gasket.

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Install the cylinder head cover, bolts and stud bolt.
Torque: 97 lb.in (11 Nm)

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NOTE: Do not use compressed air or the Fuel Injector Brush to clean the tip of the fuel injectors. Failure to follow this instruction may result in damage to the fuel injectors.

NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

Using the special tool, clean the fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.

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NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
1. Install the Teflon® Seal Guide onto the fuel injector tip. Install 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 Teflon® Seal Guide, using the Pusher Tool, slide the Teflon® seals along the Teflon® Seal Guide
3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors.
4. Remove the special tool. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
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NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
1. Massage and warm the Teflon® seal with your fingers before the Teflon® seal sizer tool is installed. This will aid in installing the Teflon® seal sizer tool.
2. NOTE: The beveled opening of the Teflon® seal sizer tool goes away from the seal.
  
  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. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
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NOTE: The new the fuel injector support rings must be installed in the correct orientation with the wide surface area facing up against the fuel injector O-ring seals. Improperly installed support rings may cause the fuel system to leak.

NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.
1. Install the new the fuel injector support rings.
2. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  Install the new fuel injector O-rings.
3. Install the new the fuel injector clips.
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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.

Install the fuel injectors in the fuel rail.

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

NOTE: No sudden impact force is allowed.

Install the fuel rail by pushing down on the fuel rail above the injectors and install the bolts.

Torque: Stage 1: Tighten to: 89 lb.in (10 Nm) - - Stage 2: Back off to: 0 lb.in (0 Nm) - - Stage 3: Wait 5 seconds: 0 turn(s) - - Stage 4: Tighten to: 124 lb.in (14 Nm) - - Stage 5: Tighten an additional: 30°

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- Install the exhaust manifold heat shield on the new CHT sensor.
- Install the CHT sensor.
  Torque: 97 lb.in (11 Nm)
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If equipped, install the engine lift eye and the bolt.
Torque: Stage 1: 33 lb.ft (45 Nm) - - Stage 2: 30°

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Install the coolant outlet and hose assembly and the bolts.
Torque: 97 lb.in (11 Nm)

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