Cylinder Head: Assembly

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

Coat the valve stems with clean engine oil and install the valve.

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NOTE: Lubricate the valve seal with clean engine oil prior to installing.

Install the valve seal.

Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal.

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

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NOTE: Install the valve collet, using some multi-purpose grease and a small screwdriver.

NOTE: 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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Repeat the appropriate installation steps for all of the other valves.
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
1. Install the Teflon® Seal Guide onto the fuel injector tip.
  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 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.
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4. Remove the special tools.
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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. 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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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 wide surface area 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 O-ring seals.
  
  NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  Install the new fuel injector O-ring seals and lubricate them with clean engine oil.
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 must slip into the groove of the fuel rail cup.

Install the fuel injectors to 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.
- Press the fuel rail down into the cylinder head injector bores by hand, then install and hand start fuel rail bolts 3 and 4. Release the force before tightening.
- Install the remaining fuel rail bolts. Tighten all of the fuel rail bolts in the sequence shown in illustration.
  Torque: 18 lb.ft (25 Nm)
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NOTE: Only use hand tools when installing the spark plugs, or damage can occur to the cylinder head or spark plug.

Install the spark plugs.

Torque: 133 lb.in (15 Nm)

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Install the new CHT sensor.
Torque: 80 lb.in (9 Nm)

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NOTE: Make sure that new studs are installed.

Install the new exhaust manifold studs.

Torque: 150 lb.in (17 Nm)

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Install the LH and RH engine lift eyes and the bolts.
Torque: 39 lb.ft (53 Nm)

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