Cylinder Head: Material

All cylinder heads 

NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in future oil leakage.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown in illustration, RH similar.
Fig 1: Locating Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
1. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 10 cylinder head bolts loosely.
NOTE: RH shown in illustration, LH similar.
2. Tighten the 10 cylinder head bolts in 3 stages, in the sequence shown in illustration.
   • Stage 1: Tighten to 40 Nm (30 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
   • Stage 3: Tighten an additional 90 degrees.
     Fig 2: Identifying Cylinder Head Bolt Tightening Sequence

     Courtesy of FORD MOTOR CO.

   LH cylinder head 

3. Remove the Cylinder Head Remover/Installer from the LH cylinder head.
   Fig 3: Identifying Special Tool Onto Cylinder Head

   Courtesy of FORD MOTOR CO.
4. Install the 12 hydraulic lash adjusters into the LH cylinder head.
   • Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
     Fig 4: Identifying Hydraulic Lash Adjusters

     Courtesy of FORD MOTOR CO.
5. Install 8 new exhaust manifold studs.
   • tighten to 12 Nm (106 lb-in).
     Fig 5: Locating Exhaust Manifold Studs

     Courtesy of FORD MOTOR CO.
6. Position a new gasket and the LH exhaust manifold and tighten the 8 new nuts in the sequence shown in illustration.
   • Tighten to 25 Nm (18 lb-ft).
     Fig 6: Identifying Bolt Loosening Sequence Of Exhaust Manifold

     Courtesy of FORD MOTOR CO.
7. Position the intake manifold vacuum tube support bracket and install the bolt.
   • Tighten to 10 Nm (89 lb-in).
     Fig 7: Locating Intake Manifold Vacuum Tube Support Bracket And Bolt

     Courtesy of FORD MOTOR CO.

   RH cylinder head 

8. Remove the Cylinder Head Remover/Installer from the RH cylinder head.
   Fig 8: Identifying Special Tool Onto Cylinder Head

   Courtesy of FORD MOTOR CO.
9. Install the 12 hydraulic lash adjusters into the RH cylinder head.
   • Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
     Fig 9: Identifying Hydraulic Lash Adjusters

     Courtesy of FORD MOTOR CO.
10. Install 8 new exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
      Fig 10: Locating Exhaust Manifold Studs

      Courtesy of FORD MOTOR CO.
11. Position a new gasket and the RH exhaust manifold and tighten the 8 new nuts in the sequence shown in illustration.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 11: Identifying Bolt Tightening Sequence Of Exhaust Manifold

      Courtesy of FORD MOTOR CO.
12. Install the coolant tube and the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 12: Identifying Coolant Tube Stud Bolt

      Courtesy of FORD MOTOR CO.

    All cylinder heads 

13. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
    Fig 13: Positioning Crankshaft

    Courtesy of FORD MOTOR CO.
14. Install the LH and RH camshafts.
    • Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
NOTE: LH shown in illustration, RH similar.
15. Install the LH and RH camshaft bearing caps in their original locations.
    • Lubricate the camshaft bearing caps with clean engine oil.
    • Position the front camshaft bearing cap.
    • Position the remaining camshaft bearing caps.
    • Install the 20 bolts loosely.
    • Tighten to 10 Nm (89 lb-in) in the sequence shown in illustration.
      Fig 14: Identifying Camshaft Bearing Cap Bolt Loosening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE: LH shown in illustration, RH similar.
Fig 15: Identifying Camshaft Phaser And Sprocket Assembly Bolt
Courtesy of FORD MOTOR CO.
16. Install the camshaft phaser and sprockets and new camshaft phaser and sprocket bolts finger-tight.
NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket.
NOTE: LH shown in illustration, RH similar.
17. Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 16: Tightening LH Camshaft Phaser And Sprocket Assembly

      Courtesy of FORD MOTOR CO.
NOTE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTE: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.
Fig 17: Compressing Tensioner Plunger Using Vise
Courtesy of FORD MOTOR CO.
18. Compress the tensioner plunger, using a vise.
19. Install the Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.
    Fig 18: Installing Retaining Clip On Tensioner

    Courtesy of FORD MOTOR CO.
20. Remove the tensioner from the vise.
21. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
    Fig 19: Locating Copper Link Timing Marks

    Courtesy of FORD MOTOR CO.
22. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 20: Installing Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
23. Position the LH and RH timing chain guides and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 21: Identifying Timing Chain Guides

      Courtesy of FORD MOTOR CO.
24. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
    Fig 22: Aligning Crankshaft Sprocket Timing Mark And Timing Chain Link

    Courtesy of FORD MOTOR CO.
NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Fig 23: Identifying Timing Mark On Timing Chain
Courtesy of FORD MOTOR CO.
25. Position the timing chain on the camshaft phaser and sprocket with the timing mark positioned between the 2 copper (marked) chain links.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
26. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 24: Identifying LH Timing Chain Tensioner Bolts

      Courtesy of FORD MOTOR CO.
27. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
    Fig 25: Removing Retaining Clip From LH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
28. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
    Fig 26: Aligning (Outer) Sprocket Timing Mark And Chain Link

    Courtesy of FORD MOTOR CO.
NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.
Fig 27: Locating Upper Stabilizer Link Nut
Courtesy of FORD MOTOR CO.
29. Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is positioned between the 2 copper (marked) chain links.
30. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 28: Identifying RH Timing Chain Tensioner Bolts

      Courtesy of FORD MOTOR CO.
31. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
    Fig 29: Removing Retaining Clip From LH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
32. As a post-check, verify correct alignment of all timing marks.
    Fig 30: Locating Timing Chain Mark Location

    Courtesy of FORD MOTOR CO.
33. Install the crankshaft sensor ring on the crankshaft.
    Fig 31: Locating Crankshaft Sensor Ring

    Courtesy of FORD MOTOR CO.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
34. Using the Valve Spring Compressor, install all of the camshaft roller followers.
    • Lubricate the camshaft roller followers with clean engine oil prior to installation.
      Fig 32: Installing Camshaft Roller Followers

      Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
Fig 33: Applying Bead Of Cylinder Head-To-Cylinder Block Surface
Courtesy of FORD MOTOR CO.
35. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown in illustration.
36. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
    Fig 34: Installing Engine Front Cover Gasket On Engine Front Cover

    Courtesy of FORD MOTOR CO.
37. Tighten the 15 engine front cover fasteners in sequence in 2 stages.

    Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

    Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

    ITEM DESCRIPTION
    
    

    Item	Part Number	Description
    1	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    2	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    3	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    4	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    5	N806177	Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
    6	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    7	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    8	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    9	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    10	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    11	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    12	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    13	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    14	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    15	W709573	Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94

    Fig 35: Identifying Engine Front Cover Fasteners Tighten Sequence

    Courtesy of FORD MOTOR CO.
38. Install the 4 front oil pan bolts in the sequence shown in in illustration 2 stages:
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten an additional 60 degrees.
      Fig 36: Identifying Front Oil Pan/Cover Bolts Tighten Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
39. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
Fig 37: Identifying Silicone Gasket Application Points
Courtesy of FORD MOTOR CO.
40. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
NOTE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.
41. Position the RH valve cover and gasket on the cylinder head and tighten the 9 fasteners in the sequence shown in illustration.
    • Tighten to 10 Nm (89 lb-in).
      Fig 38: Identifying Cylinder Head Bolt Tighten Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
42. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
Fig 39: Identifying Silicone Gasket Application Points
Courtesy of FORD MOTOR CO.
43. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
NOTE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.
44. Position the LH valve cover and gasket on the cylinder head and tighten the 10 fasteners in the sequence shown in illustration.
    • Tighten to 10 Nm (89 lb-in).
      Fig 40: Identifying Cylinder Head Bolt Tighten Sequence

      Courtesy of FORD MOTOR CO.
45. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
    Fig 41: Lubricating Engine Front Cover And Crankshaft Seal Inner Lip With Clean Engine Oil

    Courtesy of FORD MOTOR CO.
46. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Crankshaft Front Oil Seal Installer, install a new crankshaft front seal.
    Fig 42: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tools

    Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.
Fig 43: Identifying Woodruff Key Slot On Crankshaft Pulley
Courtesy of FORD MOTOR CO.
47. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
48. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
    Fig 44: Installing Crankshaft Pulley Using Special Tool

    Courtesy of FORD MOTOR CO.
49. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
      Fig 45: Installing Crankshaft Pulley Bolt And Washer

      Courtesy of FORD MOTOR CO.
50. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 46: Locating Coolant Pump Pulley And Idler Pulley Bolts

      Courtesy of FORD MOTOR CO.
51. Position the oil level indicator and tube and install the bolt.
    • Install a new O-ring seal and lubricate with clean engine oil prior to installation.
    • Tighten to 10 Nm (89 lb-in).
      Fig 47: Locating Rear Oil Level Indicator Tube Bolt

      Courtesy of FORD MOTOR CO.
52. Install the oil level indicator and tube front bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 48: Locating Front Oil Level Indicator Tube Bolt

      Courtesy of FORD MOTOR CO.
NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.
NOTE: LH shown in illustration, RH similar.
53. Install the 8 ignition coils and the 8 bolts.
    • Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
    • Tighten to 6 Nm (53 lb-in).
      Fig 49: Locating Ignition Coil Bolts

      Courtesy of FORD MOTOR CO.
54. Position the electrical harness on the engine assembly.
55. Connect the Engine Oil Pressure (EOP) switch electrical connector.
    Fig 50: Locating Engine Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
56. Connect the engine wiring harness position retainers to the front of the RH valve cover.
    Fig 51: Locating RH Valve Cover

    Courtesy of FORD MOTOR CO.
57. Connect the engine wiring harness position retainers to the front of the LH valve cover and the LH CMP  sensor electrical connector.
    Fig 52: Locating Engine Wiring Harness Position Retainers

    Courtesy of FORD MOTOR CO.
58. Install the LH radio ignition interference capacitor and the nut.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 53: Locating Radio Ignition Interference Capacitor And Stud Bolt

      Courtesy of FORD MOTOR CO.
59. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 54: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
60. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 55: Locating Engine Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
61. Connect the RH VCT  solenoid electrical connector.
    Fig 56: Locating VCT Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
62. Install the RH radio ignition interference capacitor and the nut.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 57: Locating Radio Ignition Interference Capacitor And Stud Bolt

      Courtesy of FORD MOTOR CO.
63. Connect the RH CMP  sensor electrical connector.
    Fig 58: Locating CMP Electrical Connector

    Courtesy of FORD MOTOR CO.
NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.
NOTE: Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator damage.
NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.
NOTE: Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
64. If equipped with cylinder block drain plugs, position the RH engine support insulator bracket, position the engine support insulator bracket and install 3 new bolts in 2 stages.
    • Stage 1: Tighten to 30 Nm (22 lb-ft).
    • Stage 2: Tighten an additional minimum of 60 degrees.
      Fig 59: Locating RH Engine Support Insulator Bracket Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged.
NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to remove it.
65. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the engine cooling fan onto the cooling pump pulley.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 60: Removing Cooling Fan And Clutch Assembly

      Courtesy of FORD MOTOR CO.
66. Install the Engine Lifting Bracket.
    Fig 61: Installing Engine Lifting Bracket

    Courtesy of FORD MOTOR CO.
67. Using a suitable floor crane, remove the engine from the engine stand.
68. Install the flexplate or flywheel and the 8 bolts in the sequence shown in illustration.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 62: Identifying Flexplate Bolt Tighten Sequence

      Courtesy of FORD MOTOR CO.
69. Install the engine. For additional information, refer to ENGINE .