Cylinder Head: Assembly

WARNING: This page is about a different car, the 2016 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.

All cylinder heads

1.

Install the valve.

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2.

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

Using the valve stem oil seal installer, install the valve stem seal.

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3.

Using the Valve Spring Compressor, install the valve spring, valve spring retainer and the valve collet.

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4.

Repeat the previous 3 steps for each valve.

5.

Install the spark plugs. Refer to: Engine Ignition 3.5L GTDI .

6.

Note the fuel injector seal backup ring orientation for installation.

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7.

NOTE: Do not attempt to cut the lower Teflon ® seal without first pulling it away from the fuel injector or damage to the injector may occur.

NOTE: Use care when removing the lower Teflon ® seals, not to scratch, nick or gouge the fuel injectors.
- 1.
  
  Pull the lower Teflon ® seal away from the injector.
- 2.
  
  Carefully cut and discard the lower fuel injector Teflon ® seals.

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8.

NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
- 1.
  
  Use Special Service Tool: 310-207.
- 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.
- 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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9.

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.
- 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.

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10.
- 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.
- 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.

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11.

NOTE: RH shown, LH similar.
- 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.
- Connect the fuel injector electrical connectors.

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12.

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

NOTE: Make sure that new fuel rail bolts are installed.

NOTE: Push down on the fuel rail above the injectors.

Install the fuel injectors and fuel rail assembly into the cylinder head and install the new bolts.
- Stage 1: Tighten to 71 lb.in (8 Nm)
- Stage 2: Wait 5 sec
- Stage 3: Tighten to 124 lb.in (14 Nm)
- Stage 4: Tighten an additional 30 °

Fig 1: Fuel Rail Tightening Sequence

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RH cylinder head

13.

Install the timing chain tensioner arm and timing chain guide pins.
- Tighten to 89 lb.in (10 Nm)

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14.

Install the new the studs and the exhaust manifold gasket.
- Tighten to 106 lb.in (12 Nm)

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15.

Install the exhaust manifold and the new nuts.
- Stage 1: Tighten to 168 lb.in (19 Nm)
- Stage 2: Tighten to 18 lb.ft (25 Nm)

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16.
- 1.
  
  Install the stud bolt.
  - Stage 1: Tighten to 89 lb.in (10 Nm)
  - Stage 2: Tighten an additional 20 °
- 2.
  
  Install the new CHT sensor.
  - Tighten to 97 lb.in (11 Nm)

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17.

Inspect the turbocharger coolant return tube fittings and replace as needed.

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18.

Install the turbocharger coolant return tube and fitting.
- Tighten to 159 lb.in (18 Nm)

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LH cylinder head

19.

Install the timing chain guide pin.
- Tighten to 89 lb.in (10 Nm)

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20.

Install the lift eye bracket and the bolts.
- Tighten to 18 lb.ft (24 Nm)

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21.

Install the new the studs and the exhaust manifold gasket.
- Tighten to 106 lb.in (12 Nm)

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22.

Install the exhaust manifold and the new nuts.
- Stage 1: Tighten to 168 lb.in (19 Nm)
- Stage 2: Tighten to 18 lb.ft (25 Nm)

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23.

Inspect the turbocharger coolant return tube fittings and replace as needed.

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24.

Install the turbocharger coolant return tube and fitting.
- Tighten to 159 lb.in (18 Nm)

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