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Home >> Ford >> 2022 >> Transit Connect Titanium, Gas/Ethanol >> Repair and Diagnosis >> External Pages >> Different car >> Section 412 (Engine - 3.5L ECOBOOST (272KW/370PS) (Removal - Disassembly & Assembly)) >> Disassembly And Assembly Of Subassemblies >> Cylinder Head >> Assembly

Cylinder Head: Assembly

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All cylinder heads 

  1. Install the valve.
    GFD460607Courtesy of FORD MOTOR COMPANY
  2. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.

    Using the special tool, install the valve stem seal. Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal.

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    GFD460608Courtesy of FORD MOTOR COMPANY
  3. 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., 303-1249 Valve Spring Compressor., 303-1418 Compressor, Valve Spring.
    GFD460604Courtesy of FORD MOTOR COMPANY
  4. Repeat the previous 3 steps for each valve.
  5. Install the spark plugs.

    Torque: 133 lb.in (15 Nm)

    GFD459197Courtesy of FORD MOTOR COMPANY

    RH cylinder head 

  6. 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.

    GFD460609Courtesy of FORD MOTOR COMPANY
  7. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
    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. 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.

    GFD460610Courtesy of FORD MOTOR COMPANY
    1. NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

      Install the fuel injector backup ring.

    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. Lubricate the new fuel injector O-ring seals with clean engine oil.

      Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    3. Install the new the fuel injector retaining clip.
    GFD460611Courtesy of FORD MOTOR COMPANY
  9. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD460612Courtesy of FORD MOTOR COMPANY
  10. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and direct injection fuel rail assembly into the cylinder head. Tighten the bolts in sequence shown below in 2 stages.

      Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.

    • Connect the fuel injector electrical connectors.

    Fig 1: Fuel Rail Assembly Bolts Tightening Sequence
    GFD460613Courtesy of FORD MOTOR COMPANY
  11. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not interchangeable.
    NOTE: Make sure that new fuel injector O-ring seals are installed.

    Install the new fuel injector O-ring seals and the fuel injector retaining clips onto the fuel injectors. Lubricate the new fuel injector O-ring seals with clean engine oil.

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    GFD460614Courtesy of FORD MOTOR COMPANY
  12. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD460615Courtesy of FORD MOTOR COMPANY
  13. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and port injection fuel rail assembly into the cylinder head and tighten the bolts.

      Torque: 89 lb.in (10 Nm)

    • Connect the fuel injector electrical connectors.

    GFD460616Courtesy of FORD MOTOR COMPANY
  14. NOTE: Install short end of stud into cylinder head assembly.

    • Loosely install the new studs into the cylinder head.

    • Tighten the studs in sequence shown below.

      Torque: 159 lb.in (18 Nm)

    • Install the new exhaust manifold gasket.

    Fig 2: Exhaust Manifold Studs Tightening Sequence
    GFD460617Courtesy of FORD MOTOR COMPANY
  15. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown below in 2 stages.

    Torque: Stage 1: 168 lb.in (19 Nm) Stage 2: 18 lb.ft (25 Nm)

    Fig 3: Exhaust Manifold Nuts Tightening Sequence
    GFD460618Courtesy of FORD MOTOR COMPANY
  16. Install the new CHT sensor.

    Torque: 97 lb.in (11 Nm)

    GFD460619Courtesy of FORD MOTOR COMPANY
    • Install the new turbocharger gasket by pressing the gasket into the turbocharger flange groove evenly until at least 50% of the gasket is within the groove.
    GFD460620Courtesy of FORD MOTOR COMPANY
    • NOTE: Do not use a metal brush damage to sealing area will result in leaks.

      Carefully use a nylon brush to remove the old O-ring residue, use brake cleaner to rinse the O-ring residue out of the TC tube to engine O-ring bores. Inspect the area for deep scratches and gouges. Install new components if necessary.

    • NOTE: Some models may be equipped with hex head bolts.

      Install the TC, then install and tighten the TC retainers as indicated in the following 2 stages.

      Torque: Stage 1: 24 lb.ft (32 Nm) Stage 2: 24 lb.ft (32 Nm)

    GFD460621Courtesy of FORD MOTOR COMPANY
  19. Install and tighten the TC coolant return tube bolt.

    Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 30 deg.

    GFD460590Courtesy of FORD MOTOR COMPANY
  20. Install Special Service Tool: 303-1654 Lift Eyes.

    Torque: 18 lb.ft (25 Nm)

    GFD460589Courtesy of FORD MOTOR COMPANY

    LH cylinder head 

  21. 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.

    GFD460609Courtesy of FORD MOTOR COMPANY
  22. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
    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. 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.

    GFD460610Courtesy of FORD MOTOR COMPANY
    1. NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

      Install the fuel injector backup ring.

    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. Lubricate the new fuel injector O-ring seals with clean engine oil.

      Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    3. Install the new the fuel injector retaining clip.
    GFD460611Courtesy of FORD MOTOR COMPANY
  24. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD460622Courtesy of FORD MOTOR COMPANY
  25. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and direct injection fuel rail assembly into the cylinder head. Tighten the bolts in sequence shown below in 2 stages.

      Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.

    • Connect the fuel injector electrical connectors.

    Fig 4: Fuel Rail Assembly Bolts Tightening Sequence
    GFD460623Courtesy of FORD MOTOR COMPANY
  26. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not interchangeable.
    NOTE: Make sure that new fuel injector O-ring seals are installed.

    Install the new fuel injector O-ring seals and the fuel injector retaining clips onto the fuel injectors. Lubricate the new fuel injector O-ring seals with clean engine oil.

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

    GFD460614Courtesy of FORD MOTOR COMPANY
  27. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD460624Courtesy of FORD MOTOR COMPANY
  28. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and port injection fuel rail assembly into the cylinder head and tighten the bolts.

      Torque: 89 lb.in (10 Nm)

    • Connect the fuel injector electrical connectors.

    GFD460625Courtesy of FORD MOTOR COMPANY
  29. NOTE: Install short end of stud into cylinder head assembly.

    • Loosely install the new studs into the cylinder head.

    • Tighten the studs in sequence shown below.

      Torque: 159 lb.in (18 Nm)

    • Install the new exhaust manifold gasket.

    Fig 5: Exhaust Manifold Studs Tightening Sequence
    GFD460626Courtesy of FORD MOTOR COMPANY
  30. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown below in 2 stages.

    Torque: Stage 1: 168 lb.in (19 Nm) Stage 2: 18 lb.ft (25 Nm)

    Fig 6: Exhaust Manifold Nuts Tightening Sequence
    GFD460627Courtesy of FORD MOTOR COMPANY
    • Install the new turbocharger gasket by pressing the gasket into the turbocharger flange groove evenly until at least 50% of the gasket is within the groove.
    GFD460628Courtesy of FORD MOTOR COMPANY
    • NOTE: Do not use a metal brush damage to sealing area will result in leaks.

      Carefully use a nylon brush to remove the old O-ring residue, use brake cleaner to rinse the O-ring residue out of the TC tube to engine O-ring bores. Inspect the area for deep scratches and gouges. Install new components if necessary.

    • NOTE: Some models may be equipped with hex head bolts.

      Install the TC, then install and tighten the TC retainers as indicated in the following 2 stages.

      Torque: Stage 1: 24 lb.ft (32 Nm) Stage 2: 24 lb.ft (32 Nm)

    GFD460629Courtesy of FORD MOTOR COMPANY
  33. Install and tighten the TC coolant return tube bolt.

    Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 30 deg.

    GFD460574Courtesy of FORD MOTOR COMPANY
  34. Install Special Service Tool: 303-1654 Lift Eyes.

    Torque: 18 lb.ft (25 Nm)

GFD460573Courtesy of FORD MOTOR COMPANY
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