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Home >> Ford >> 2024 >> E-Transit Cutaway >> Repair and Diagnosis >> External Pages >> Different car >> Section 152 (Engine - 3.5L DURATEC (202KW/275PS)) >> Disassembly And Assembly Of Subassemblies >> Cylinder Head >> Assembly

Cylinder Head: Assembly

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All cylinder heads 

NOTE: LH shown, RH similar.
  1. Install the valve.
    GFD838725Courtesy of FORD MOTOR COMPANY
  2. 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.

    GFD838726Courtesy 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.
    GFD838136Courtesy of FORD MOTOR COMPANY
  4. Repeat the previous 3 steps for each valve.
  5. 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: 15 Nm

    GFD838723Courtesy of FORD MOTOR COMPANY

    RH cylinder head 

    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.
    GFD838142Courtesy 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.

    GFD838143Courtesy 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.

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

    3. Install the new the fuel injector clip.
    GFD838727Courtesy of FORD MOTOR COMPANY
  9. NOTE: The fuel injectors are held in by the O-ring seal only.

    Install the fuel injectors into the fuel rail.

    GFD838728Courtesy of FORD MOTOR COMPANY
  10. Connect the fuel injector electrical connectors.
    GFD838719Courtesy of FORD MOTOR COMPANY
  11. Apply grease to the tip of the fuel injectors.

    Material: Grease - High Temperature (WSS-M1C267-A1)

    GFD838146Courtesy of FORD MOTOR COMPANY
  12. Apply grease to the top of the fuel injector bores.

    Material: Grease - High Temperature (WSS-M1C267-A1)

    GFD838147Courtesy of FORD MOTOR COMPANY
  13. 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 in 2 stages.

      Torque: Stage 1: 10 Nm Stage 2: 45deg.

    • Connect the fuel injector electrical connectors.

    GFD838729Courtesy of FORD MOTOR COMPANY
  14. Install a new CHT sensor.

    Torque: 10 Nm

    GFD838730Courtesy of FORD MOTOR COMPANY
  15. Install the timing chain tensioner arm guide pins.

    Torque: Stage 1: 20 Nm Stage 2: 60deg.

    GFD838716Courtesy of FORD MOTOR COMPANY
    • Install the new the exhaust manifold studs.

      Torque: 12 Nm

    • Install a new exhaust manifold gasket.

    GFD838731Courtesy of FORD MOTOR COMPANY
  17. Install the exhaust manifold and the new nuts.

    Torque: Stage 1: 19 Nm Stage 2: 25 Nm

    GFD838732Courtesy of FORD MOTOR COMPANY
  18. Install the exhaust manifold heat shield and the bolts.

    Torque: 12 Nm

    GFD838713Courtesy of FORD MOTOR COMPANY

    LH cylinder head 

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

    1. Install the Arbor on the fuel injector tipsUse 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.

    GFD838142Courtesy of FORD MOTOR COMPANY
  20. 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.

    GFD838143Courtesy 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.

    3. Install the new the fuel injector clip.
    GFD838727Courtesy of FORD MOTOR COMPANY
  22. NOTE: The fuel injectors are held in by the O-ring seal only.

    Install the fuel injectors into the fuel rail.

    GFD838733Courtesy of FORD MOTOR COMPANY
  23. Connect the fuel injector electrical connectors.
    GFD838708Courtesy of FORD MOTOR COMPANY
  24. 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 in 2 stages.

      Torque: Stage 1: 10 Nm Stage 2: 45deg.

    • Connect the fuel injector electrical connectors.

    GFD838734Courtesy of FORD MOTOR COMPANY
  25. Install the timing chain guide pin.

    Torque: Stage 1: 20 Nm Stage 2: 60deg.

    GFD838706Courtesy of FORD MOTOR COMPANY
    • Install the new the exhaust manifold studs.

      Torque: 12 Nm

    • Install a new exhaust manifold gasket.

    GFD838735Courtesy of FORD MOTOR COMPANY
  27. Install the exhaust manifold and the new nuts.

    Torque: Stage 1: 19 Nm Stage 2: 25 Nm

    GFD838736Courtesy of FORD MOTOR COMPANY
  28. Install the exhaust manifold heat shield and the bolts.

    Torque: 12 Nm

    GFD838703Courtesy of FORD MOTOR COMPANY
  29. Install the heat shield and the bolts.

    Torque: 20 Nm

GFD838702Courtesy of FORD MOTOR COMPANY
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